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Section 1263 (Engine - 3.9): Assembly: Engine

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
ENGINE ASSEMBLY SPECIAL TOOLS

G03996696
 Installer, Crankshaft Front Oil Seal 303-646
G03901093
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
G03996387
 Aligner, Camshaft 303-530
G04007654
 Tensioner, Timing Chain 303-532
G03996700
 Alignment Gauge, Crankshaft 303-645
G03996315
 Remover/Installer, Crankshaft Rear Oil Seal 303-647
G03996702
 Adapter for 204-185 204-208 (T95T-5310-AR2)
G03898369
 Lifting Brackets, Engine 303-050 (T70P-6000)
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3)
ENGINE ASSEMBLY MATERIAL SPECIFICATION

Item Specification
Motorcraft Metal Surface Cleaner ZC-21 WSE-M5B392-A
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent WSS-M2C930-A
Fig 1: Identifying Components Of Cylinder Head And Valve Train
G03996705Courtesy of FORD MOTOR CO.
Fig 2: Identifying Components Of Lower End
G03996706Courtesy of FORD MOTOR CO.
Fig 3: Identifying Components Of Lower End Exterior Dress
G03996707Courtesy of FORD MOTOR CO.
Fig 4: Identifying Components Of Upper End Exterior Dress
G03996708Courtesy of FORD MOTOR CO.
  1. Install the knock sensors (KS) and 2 bolts. Tighten to 20 Nm (15 lb-ft).
    Fig 5: Locating Knock Sensors
    G03996686Courtesy of FORD MOTOR CO.
  2. Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
    3. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean and dry.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
    CAUTION: Cylinder head machining or milling is not authorized by Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
    CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
    Fig 6: Positioning Cylinder Head On Block
    G03996710Courtesy of FORD MOTOR CO.
  3. Install new gaskets and position the cylinder heads on the engine.
    4. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always use new bolts.
    Fig 7: Identifying Tightening Sequence Of RH Head Bolts
    G03996711Courtesy of FORD MOTOR CO.
  4. Install and tighten the RH head bolts in 4 stages in the sequence shown.
    • Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
  5. Install the 2 bolts and tighten in 2 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 8: Identifying RH Cylinder Head End Bolts
    G03996510Courtesy of FORD MOTOR CO.
  6. Install and tighten the LH head bolts in 4 stages in the sequence shown.
    • Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
    Fig 9: Identifying Tightening Sequence Of LH Head Bolts
    G03996713Courtesy of FORD MOTOR CO.
  7. Install the 2 bolts and tighten in 2 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 10: Identifying LH Cylinder Head End Bolts
    G03996714Courtesy of FORD MOTOR CO.
    8. NOTE: Coat the valve tappets with clean engine oil prior to installing.
    Fig 11: Installing Valve Tappets And Shims
    G03996398Courtesy of FORD MOTOR CO.
  8. Install the valve tappets and shims in their original location.
    9. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
    Fig 12: Locating RH Camshafts On Camshaft Journals
    G03996512Courtesy of FORD MOTOR CO.
  9. Position the RH camshafts on the camshaft journals.
    10. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 13: Identifying Tightening Sequence Of RH Bearing Cap Bolts
    G03996396Courtesy of FORD MOTOR CO.
  10. Install the RH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bearing cap bolts. Tighten the bolts in 3 stages in the sequence shown.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 Nm (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
    11. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
    Fig 14: Positioning LH Camshafts On Camshaft Journals
    G03996392Courtesy of FORD MOTOR CO.
  11. Position the LH camshafts on the camshaft journals.
    12. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 15: Identifying Tightening Sequence Of LH Bearing Cap Bolts
    G03996394Courtesy of FORD MOTOR CO.
  12. Install the LH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bearing cap bolts. Tighten the bolts in 3 stages in the sequence shown.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 Nm (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
    13. CAUTION: If any components are installed new, the engine must be reshimmed or engine damage can occur.
    Fig 16: Checking Clearance Using Feeler Gauge
    G03995833Courtesy of FORD MOTOR CO.
  13. Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to VALVE CLEARANCE CHECK  in this article.
  14. If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to VALVE CLEARANCE ADJUSTMENT  in this article .
  15. Install the engine lifting equipment and remove the engine from the stand.
    16. CAUTION: The plastic sleeve that comes with the new crankshaft rear oil seal protects the seal while in transit and is also used as an installation tool to prevent lip seal roll when carrying out the repair. The sleeve must be used to prevent future seal concerns.
    NOTE: Lubricate the cylinder block bore and the crankshaft with clean engine oil before installing the seal.
    Fig 17: Positioning Rear Oil Seal With Protective Installer
    G03996318Courtesy of FORD MOTOR CO.
  16. Position the rear oil seal with protective installer onto the end of the crankshaft.
  17. Using the special tool, install the rear main seal.
    Fig 18: Installing Rear Main Seal
    G03996722Courtesy of FORD MOTOR CO.
  18. Install the flexplate and tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 15 Nm (11 lb-ft).
    • Stage 2: Tighten to 110 Nm (81 lb-ft).
    Fig 19: Tightening Flexplate Bolts In Sequence
    G03996314Courtesy of FORD MOTOR CO.
  19. Mount the engine on a suitable engine stand.
    20. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
    Fig 20: Identifying Special Tool
    G03996341Courtesy of FORD MOTOR CO.
  20. Install the special tool.
    • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
    • Install the special tool.
    21. NOTE: LH shown, RH similar.
    Fig 21: Identifying Camshafts Flats
    G03996843Courtesy of FORD MOTOR CO.
  21. Position all of the camshafts so the flats of the camshafts are facing upward.
  22. Install the LH secondary timing chain tensioner and 2 bolts.
    • Tighten to 11 Nm (8 lb-ft).
  23. Install the LH variable cam timing (VCT) unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 22: Installing LH Variable Cam Timing Unit
    G03996726Courtesy of FORD MOTOR CO.
  24. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
    Fig 23: Installing LH VCT Unit
    G03996845Courtesy of FORD MOTOR CO.
  25. Remove the locking pin from the LH secondary timing chain tensioner.
    Fig 24: Locating Locking Pin For LH Secondary Timing Chain Tensioner
    G03996359Courtesy of FORD MOTOR CO.
  26. Install the RH secondary timing chain tensioner and 2 bolts.
    • Tighten to 11 Nm (8 lb-ft).
  27. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 25: Identifying RH VCT Unit
    G03996358Courtesy of FORD MOTOR CO.
  28. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
    Fig 26: Identifying RH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain
    G03996362Courtesy of FORD MOTOR CO.
  29. Remove the locking pin from the RH secondary timing chain tensioner.
    Fig 27: Locating Locking Pin For RH Secondary Timing Chain Tensioner
    G03996357Courtesy of FORD MOTOR CO.
  30. Reset the timing chain tensioners.
    1. Hold the lever toward the tensioner piston.
    2. Using finger pressure, compress the tensioner.
    3. Push the lever down and install a drill rod to lock the piston.
    Fig 28: Compressing Tensioner
    G03996367Courtesy of FORD MOTOR CO.
    31. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 29: Identifying Special Tool
    G03996351Courtesy of FORD MOTOR CO.
  31. Install the special tool on the LH head.
  32. Position the LH timing chain and crankshaft gear.
    • Position the timing chain over the LH intake camshaft sprocket.
    • Position the crankshaft gear in the timing chain.
    Fig 30: Identifying LH Timing Chain And Crankshaft Gear
    G03996356Courtesy of FORD MOTOR CO.
  33. Install the LH timing chain guide and bolt.
    • Tighten to 11 Nm (8 lb-ft).
    Fig 31: Identifying LH Timing Chain Guide And Bolt
    G03996355Courtesy of FORD MOTOR CO.
  34. Install the LH timing chain tensioner arm and nut.
    • Tighten to 11 Nm (8 lb-ft).
    Fig 32: Identifying LH Timing Chain Tensioner Arm And Nut
    G03996354Courtesy of FORD MOTOR CO.
  35. Install the LH timing chain tensioner.
    • Install the timing chain tensioner and bolts, and remove the drill rod.
    Fig 33: Installing Timing Chain Tensioner Bolts
    G03996737Courtesy of FORD MOTOR CO.
    36. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    CAUTION: Using the special tool, apply 10 Nm (89 lb-in) counterclockwise to the LH exhaust camshaft sprocket.
    Fig 34: Tightening LH Exhaust Camshaft Sprocket And Variable Camshaft Timing Bolts
    G03996373Courtesy of FORD MOTOR CO.
  36. Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in 2 stages.
    • Stage 1: Tighten to 35 Nm (26 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  37. Remove the special tool.
    Fig 35: Identifying Special Tool
    G03996351Courtesy of FORD MOTOR CO.
    38. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 36: Identifying Special Tool On RH Cylinder Head
    G03996343Courtesy of FORD MOTOR CO.
  38. Install the special tool on the right cylinder head.
  39. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
    Fig 37: Identifying RH Primary Timing Chain
    G03996349Courtesy of FORD MOTOR CO.
  40. Install the RH timing chain guide and bolt.
    • Tighten to 11 Nm (8 lb-ft).
    Fig 38: Identifying Bolt And RH Timing Chain Guide
    G03996377Courtesy of FORD MOTOR CO.
  41. Install the RH timing chain tensioner arm.
    • Tighten to 11 Nm (8 lb-ft).
    Fig 39: Identifying RH Timing Chain Tensioner Arm
    G03996347Courtesy of FORD MOTOR CO.
  42. Install the RH timing chain tensioner.
    • Install the timing chain tensioner and bolts, and remove the drill rod.
    Fig 40: Installing Timing Chain Tensioner Bolts
    G03996744Courtesy of FORD MOTOR CO.
    43. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    CAUTION: Using the special tool, apply 10 Nm (89 lb-in) counterclockwise to the RH exhaust camshaft sprocket.
    Fig 41: Tightening RH Exhaust Camshaft Sprocket And VCT Unit Bolts
    G03996380Courtesy of FORD MOTOR CO.
  43. Tighten the RH exhaust camshaft sprocket and VCT unit bolts in 2 stages.
    • Stage 1: Tighten to 35 Nm (26 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  44. Remove the special tool.
    Fig 42: Identifying Special Tool On RH Cylinder Head
    G03996343Courtesy of FORD MOTOR CO.
  45. Remove the special tool.
    Fig 43: Identifying Special Tool
    G03996341Courtesy of FORD MOTOR CO.
    46. NOTE: Lubricate the VCT bush carrier seals with clean engine oil.
    Fig 44: Identifying RH And LH Variable Cam Timing Bush Carriers, Bolts & Nuts
    G03996382Courtesy of FORD MOTOR CO.
  46. Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting the bolts and nut.
    • Tighten the bolts to 20 Nm (15 lb-ft).
    • Tighten the nut to 10 Nm (89 lb-in).
    47. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the sump is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 45: Identifying Proper Application Of Silicone Gasket
    G03996749Courtesy of FORD MOTOR CO.
  47. Apply 3 continuous beads of silicone gasket and sealant to the areas shown.
  48. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in 2 stages.
    • Stage 1: Tighten to 15 Nm (11 lb-ft).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    Fig 46: Installing Oil Sump
    G03996750Courtesy of FORD MOTOR CO.
  49. Install the oil pump and the 4 bolts. Tighten to 12 Nm (9 lb-ft).
    Fig 47: Installing Oil Pump Bolts
    G03996657Courtesy of FORD MOTOR CO.
    50. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary. Lubricate the O-ring seal with clean engine oil.
    Fig 48: Installing Oil Pump Screen Cover
    G03996656Courtesy of FORD MOTOR CO.
  50. Install the oil pump screen cover and tube.
    • Tighten to 12 Nm (9 lb-ft).
    51. NOTE: Make sure all gasket sealing surfaces are clean and dry.
    Fig 49: Identifying Tightening Sequence Of Oil Pan Bolts
    G03996406Courtesy of FORD MOTOR CO.
  51. Install a new oil pan gasket, oil pan and 17 bolts.
    • Tighten the bolts in the sequence shown in 2 stages.
      • Stage 1: Tighten to 5 Nm (44 lb-in).
      • Stage 2: Tighten to 12 Nm (9 lb-ft).
  52. Install new engine front cover gaskets.
    Fig 50: Installing New Engine Front Cover Gaskets
    G03996329Courtesy of FORD MOTOR CO.
    53. NOTE: If the front cover is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 51: Locating Silicone Gasket And Sealant Application Points
    G03996330Courtesy of FORD MOTOR CO.
  53. Apply silicone gasket and sealant in the 8 places shown.
  54. Install the engine front cover.
    • Position the engine front cover on the cylinder block.
    • Loosely install the bolts.
    • Tighten the bolts in 2 stages in the sequence shown.
      • Stage 1: Tighten to 5 Nm (44 lb-in).
      • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 52: Installing Engine Front Cover
    G03996756Courtesy of FORD MOTOR CO.
    55. NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.
    Fig 53: Installing New Front Crankshaft Seal
    G03996311Courtesy of FORD MOTOR CO.
  55. Using the special tool, install a new front crankshaft seal.
    56. NOTE: If the crankshaft pulley is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 54: Applying Bead Of Silicone Gasket And Sealant To Keyway
    G03996304Courtesy of FORD MOTOR CO.
  56. Apply a bead of silicone gasket and sealant to the keyway.
  57. Using the special tool, install the crankshaft pulley.
    Fig 55: Installing Crankshaft Pulley
    G03996305Courtesy of FORD MOTOR CO.
  58. Install a new bolt and using the special tool to hold the pulley, tighten in 4 stages.
    • Stage 1: Tighten to 80 Nm (59 lb-ft).
    • Stage 2: Loosen the bolt 2 complete turns.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 56: Identifying Special Tool To Hold Pulley
    G03996436Courtesy of FORD MOTOR CO.
  59. Install the 16 new exhaust manifold studs.
    • Tighten to 19 Nm (14 lb-ft).
    60. NOTE: LH shown, RH similar.
    Fig 57: Locating LH Exhaust Manifold Heat Shield Stud Bolt
    G03996482Courtesy of FORD MOTOR CO.
  60. Install the 2 new exhaust manifold gaskets and the 2 heat shield stud bolts.
    • Tighten to 50 Nm (37 lb-ft).
  61. Install the LH exhaust manifold and the 8 new nuts.
    • Tighten the nuts to 25 Nm (18 lb-ft) in the sequence shown.
    Fig 58: Identifying Tightening Sequence Of LH Exhaust Manifold Nuts
    G03996418Courtesy of FORD MOTOR CO.
  62. Install the RH exhaust manifold and the 8 new nuts.
    • Tighten the nuts to 25 Nm (18 lb-ft) in the sequence shown.
    Fig 59: Tightening Nuts Sequence Of RH Exhaust Manifold Nuts
    G03996414Courtesy of FORD MOTOR CO.
    63. NOTE: LH shown, RH similar.
    Fig 60: Identifying Bolts And Exhaust Manifold Heat Shield
    G03996480Courtesy of FORD MOTOR CO.
  63. Install the 2 exhaust manifold heat shields and 8 bolts.
    • Tighten to 3 Nm (27 lb-in).
  64. Install a new gasket, EGR tube and 2 nuts.
    • Tighten to 20 Nm (15 lb-ft).
    Fig 61: Locating Nuts And EGR Tube
    G03996476Courtesy of FORD MOTOR CO.
    65. NOTE: RH shown, LH similar.
    Fig 62: Installing New Valve Cover Gaskets
    G03996293Courtesy of FORD MOTOR CO.
  65. Install new valve cover gaskets.
    66. NOTE: RH shown, LH similar.
    NOTE: If the valve covers are not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 63: Identifying Silicone Gasket And Sealant Application Points
    G03996285Courtesy of FORD MOTOR CO.
  66. Apply 4 beads of silicone gasket and sealant as shown.
  67. Install the LH valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
    Fig 64: Identifying Tightening Sequence Of LH Valve Cover Nuts
    G03996768Courtesy of FORD MOTOR CO.
  68. Install the RH valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
    Fig 65: Identifying Tightening Sequence Of RH Valve Cover Nuts
    G03996769Courtesy of FORD MOTOR CO.
  69. Install a new gasket and the coolant pump.
    • Install the 5 bolts and tighten in 2 stages.
      • Stage 1: Tighten to 8 Nm (71 lb-in).
      • Stage 2: Tighten an additional 90 degrees.
    Fig 66: Identifying Bolts And Coolant Pump
    G03996642Courtesy of FORD MOTOR CO.
  70. Install the throttle body coolant hose.
    Fig 67: Installing Throttle Body Coolant Hose
    G03996641Courtesy of FORD MOTOR CO.
  71. Install a new O-ring seal, the coolant inlet housing and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 68: Installing New O-Ring Seal
    G03996640Courtesy of FORD MOTOR CO.
  72. Install new O-ring seals, the coolant bypass housing and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
  73. Install new intake manifold gaskets.
    Fig 69: Intake Manifold Gasket Locations
    G03996773Courtesy of FORD MOTOR CO.
  74. Install the intake manifold, the 7 bolts and the 3 studs.
    • Tighten the 7 bolts and the 3 studs in the sequence shown to 20 Nm (15 lb-ft).
    Fig 70: Identifying Intake Manifold Bolts Loosening/Tightening Sequence
    G03996271Courtesy of FORD MOTOR CO.
  75. Connect the 2 throttle body coolant hoses.
    Fig 71: Locating Throttle Body Coolant Hoses
    G03996468Courtesy of FORD MOTOR CO.
    76. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    Fig 72: Installing Fuel Injectors And Clips Onto Fuel Rail
    G03996635Courtesy of FORD MOTOR CO.
  76. Install 16 new O-ring seals onto the fuel injectors.
    • Lubricate the O-ring seals with clean engine oil.
    • Install the fuel injectors and clips onto the fuel rail.
  77. Install the fuel rail and injector assembly and the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 73: Installing Fuel Rail And Injector Assembly Bolts
    G03996634Courtesy of FORD MOTOR CO.
    78. NOTE: RH shown, LH similar.
    Fig 74: Identifying Radio Interference Ignition Capacitors Mounting Bracket And Nuts
    G03996467Courtesy of FORD MOTOR CO.
  78. Install the 2 radio interference ignition capacitors and nuts.
    • Tighten to 10 Nm (89 lb-in).
  79. Install a new gasket, the exhaust gas recirculation (EGR) system module and bolts.
    • Tighten the bolts to 25 Nm (18 lb-ft).
    • Tighten the EGR tube nut to 40 Nm (30 lb-ft).
    Fig 75: Tightening EGR Bolts
    G03996632Courtesy of FORD MOTOR CO.
  80. Install the starter motor and 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 76: Installing Starter Motor Bolts
    G03996631Courtesy of FORD MOTOR CO.
  81. Install the generator bracket and 4 bolts.
    • Tighten to 42 Nm (31 lb-ft).
    Fig 77: Installing Generator Bracket Bolts
    G03996630Courtesy of FORD MOTOR CO.
  82. Install the generator, the bolt and the 2 nuts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 78: Installing Generator
    G03996629Courtesy of FORD MOTOR CO.
  83. Install the crankcase vent tube.
    Fig 79: Identifying Crankcase Vent Tube
    G03996465Courtesy of FORD MOTOR CO.
  84. Install the 8 ignition coils and bolts.
    • Tighten to 5 Nm (44 lb-in).
    Fig 80: Identifying Bolts And Ignition Coils
    G03996464Courtesy of FORD MOTOR CO.
    85. CAUTION: Failure to lubricate the O-ring seal and the oil level indicator tube-to-engine block mating surface with clean engine oil can result in engine oil leaks.
    CAUTION: Make sure the O-ring seal remains in position and does not roll up the indicator tube during installation.
    Fig 81: Locating Nut And Oil Level Indicator Tube
    G03996463Courtesy of FORD MOTOR CO.
  85. Install a new O-ring seal, oil level indicator tube and nut.
    • Lubricate the new O-ring seal and engine mating surface with clean engine oil.
    • Tighten to 6 Nm (53 lb-in).
  86. Install the crankshaft position (CKP) sensor and bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 82: Identifying Bolt And CKP Sensor
    G03996486Courtesy of FORD MOTOR CO.
  87. Position the engine wiring harness onto the engine.
  88. Attach the heated oxygen sensor (HO2S) electrical connectors onto the brackets.
    Fig 83: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Brackets
    G03996462Courtesy of FORD MOTOR CO.
  89. Connect the generator electrical connector and wiring harness retainers.
    Fig 84: Identifying Generator Electrical Connector, Wiring Harness And Retainers
    G03996461Courtesy of FORD MOTOR CO.
  90. Connect the wiring harness retainers to the RH valve cover.
    Fig 85: Locating Wiring Harness Retainers At RH Valve Cover
    G03996622Courtesy of FORD MOTOR CO.
  91. Connect the CKP sensor electrical connector and wiring harness retainers.
    Fig 86: Identifying CKP Sensor Electrical Connector And Wiring Harness
    G03996459Courtesy of FORD MOTOR CO.
  92. Attach the wiring harness onto the front cover.
    Fig 87: Locating Wiring Harness At Front Cover
    G03996458Courtesy of FORD MOTOR CO.
  93. Connect the wiring harness retainers to the LH valve cover.
    Fig 88: Locating Wiring Harness Retainers At LH Valve Cover
    G03996457Courtesy of FORD MOTOR CO.
  94. Install the power steering bracket and 5 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 89: Identifying Power Steering Bracket And Bolts
    G03996456Courtesy of FORD MOTOR CO.
    95. NOTE: RH shown, LH similar.
    Fig 90: Locating VCT Sensor Electrical Connectors
    G03996455Courtesy of FORD MOTOR CO.
  95. Connect the 2 VCT sensor electrical connectors.
  96. Connect the KS and CMP sensor electrical connectors.
    • Attach the pin-type retainers.
    Fig 91: Locating KS And CMP Sensor Electrical Connectors
    G03996454Courtesy of FORD MOTOR CO.
    97. NOTE: LH shown, RH similar.
    Fig 92: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G03996269Courtesy of FORD MOTOR CO.
  97. Connect the 8 fuel injectors and the 2 radio interference capacitor electrical connectors.
    98. NOTE: RH shown, LH similar.
    Fig 93: Identifying Engine Appearance Cover Brackets And Nuts
    G03996452Courtesy of FORD MOTOR CO.
  98. Install the 2 engine appearance cover brackets and the 4 nuts.
    • Tighten to 6 Nm (53 lb-in).
  99. Attach the vacuum hose retainers onto the LH engine appearance cover support bracket.
    Fig 94: Locating Vacuum Hose Retainers
    G03996451Courtesy of FORD MOTOR CO.
    100. NOTE: LH shown, RH similar.
    Fig 95: Identifying Engine Wiring Harness
    G03996450Courtesy of FORD MOTOR CO.
  100. Connect the engine wiring harness retainers to the engine appearance cover support brackets.
  101. Connect the 8 ignition coil electrical connectors.
    Fig 96: Identifying Ignition Coil Electrical Connectors
    G03996441Courtesy of FORD MOTOR CO.
    102. NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.
    Fig 97: Applying Bead Of Silicone Sealer
    G03996801Courtesy of FORD MOTOR CO.
  102. Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
  103. Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wiring harness and notch.
    Fig 98: Applying Bead Of Silicone Sealer
    G03996802Courtesy of FORD MOTOR CO.
  104. Install the ignition coil covers.
    • Tighten to 10 Nm (89 lb-in).
    Fig 99: Tightening Ignition Coil Covers Bolts
    G03996803Courtesy of FORD MOTOR CO.
  105. Install the vacuum harness.
    Fig 100: Identifying Vacuum Harness
    G03996449Courtesy of FORD MOTOR CO.
  106. Connect the coolant vent hose to the coolant outlet.
    Fig 101: Identifying Coolant Vent Hose To Coolant Outlet
    G03996448Courtesy of FORD MOTOR CO.
  107. Connect the EGR system module electrical connector.
    Fig 102: Connecting EGR System Module Electrical Connector
    G03996447Courtesy of FORD MOTOR CO.
  108. Connect the fuel rail temperature sensor electrical connector.
    Fig 103: Locating Fuel Rail Temperature Sensor Electrical Connector
    G03996446Courtesy of FORD MOTOR CO.
  109. Connect the evaporative emissions (EVAP) tube.
    Fig 104: Locating Evaporative Emissions Tube
    G03996445Courtesy of FORD MOTOR CO.
  110. Connect the electronic throttle body electrical connector.
    Fig 105: Locating Electronic Throttle Body Electrical Connector
    G03996444Courtesy of FORD MOTOR CO.
  111. Connect the fuel pressure sensor electrical connector.
    Fig 106: Locating Fuel Pressure Sensor Electrical Connector
    G03996443Courtesy of FORD MOTOR CO.
  112. Connect the throttle position (TP) sensor electrical connector.
    Fig 107: Identifying Throttle Position (TP) Sensor Electrical Connector
    G03996442Courtesy of FORD MOTOR CO.
  113. Using the special tool, install the coolant pump pulley and 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 108: Installing Coolant Pump Pulley Bolts
    G03996920Courtesy of FORD MOTOR CO.
  114. Remove the bolt and the accessory drive belt tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 109: Locating Bolt And Accessory Drive Belt Tensioner
    G03996433Courtesy of FORD MOTOR CO.
  115. Install new O-ring seals, the oil filter adapter and 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 110: Locating Oil Filter Adapter Mounting Bolts
    G03996598Courtesy of FORD MOTOR CO.
    116. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
    NOTE: Lubricate the gasket with clean engine oil.
    Fig 111: Tightening Oil Cooler Bolt
    G03996597Courtesy of FORD MOTOR CO.
  116. Position the new oil cooler, new gasket and install the bolt.
    • Rotate the cooler clockwise until the locating pin hits the stop.
    • Tighten the bolt to 60 Nm (44 lb-ft).
    117. NOTE: Lubricate the gasket with clean engine oil.
  117. Install a new oil filter and gasket until the seal makes contact.
    • Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
  118. Connect the oil pressure and oil temperature sensor electrical connectors.
    Fig 112: Locating Oil Pressure And Oil Temperature Sensor Electrical Connectors
    G03996596Courtesy of FORD MOTOR CO.
  119. Install the engine block drain plug.
    • Tighten to 50 Nm (37 lb-ft).
  120. Install the LH engine mount bracket, stud bolt and 3 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 113: Tightening LH Engine Mount Bracket Bolts
    G03996595Courtesy of FORD MOTOR CO.
  121. Install the RH engine mount bracket, stud bolt and 3 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 114: Tightening RH Engine Mount Bracket Bolts
    G03996594Courtesy of FORD MOTOR CO.
  122. Install the special tool.
    Fig 115: Installing Special Tool
    G03996580Courtesy of FORD MOTOR CO.
  123. Install the special tool.
    Fig 116: Installing Special Tool
    G03996820Courtesy of FORD MOTOR CO.
  124. Install the engine lifting equipment and remove the engine from the stand.
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