Engine Block

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the oil squirters are being reused, they must be installed in the same location as marked during disassembly.

NOTE: The front bulkhead does not have an oil squirter.

Install the 4 oil squirters.
- Tighten to 4 Nm (35 lb-in).
Fig 1: Locating Oil Squirters
Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the smallest diameter for each journal.

Fig 2: Identifying Measuring Directions Of Crankshaft Main Bearing Journal Diameter
Position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.

Fig 3: Locating Main Bearing Beam
Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
Fig 4: Identifying Main Bearing Beam Bolts Tightening Sequence
Measure each crankshaft block main bearing bore diameter.
- Remove the bolts and the main bearing beam.
- Discard the main bearing beam bolts.
Fig 5: Identifying Crankshaft Block Main Bearing Bore Diameter
Using the chart, select the crankshaft main bearings.

Fig 6: Crankshaft Main Bearings Chart
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

Using the original connecting rod cap bolts, install the connecting caps and bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each connecting rod.
- Remove the bolts and the connecting rod cap.
- Discard the connecting rod cap bolts.
Fig 7: Identifying Connecting Rod Large End Bore Measuring Directions
Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record the smallest measurement for each connecting rod journal.

Fig 8: Identifying Measuring Directions Of Crankshaft Connecting Rod Bearing Journal Diameters
Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.

Fig 9: Connecting Rod Bearings Chart
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

NOTE: The center bulkhead is the thrust bearing.

Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the cylinder block.

Fig 10: Locating Upper Crankshaft Main Bearings
NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in the main bearing beam.

Fig 11: Locating Crankshaft Main Bearings
Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

Fig 12: Locating Crankshaft
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.

Fig 13: Locating Main Bearing Beam Side Fit Surfaces
Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face of the engine block.

Fig 14: Locating Main Bearing Beam
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads with clean engine oil.

NOTE: Position the crankshaft to the rear of the cylinder block, then position the crankshaft to the front of the cylinder block before tightening the main bearing beam bolts.

Install and tighten the 10 new main bearing beam bolts.
- Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
Fig 15: Identifying Main Bearing Beam Bolts Tightening Sequence
Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
- Position the crankshaft to the rear of the cylinder block.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
- Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play exceeds the specified range, install new parts as necessary.
Fig 16: Measuring Crankshaft End Play
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.

NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.

NOTE: Make sure the piston arrow on top is facing toward the front of the engine.

Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod assemblies.
- When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60 degrees apart from each other and a minimum of 90 degrees from the expander gap.
- The position of the upper and lower compression ring gaps are not controlled for installation.
Fig 17: Identifying Piston Ring Compressor And Connecting Rod Installer
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders 1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install connecting rod caps and bolts on connecting rods for cylinders 2 and 3 and tighten.

NOTE: After installation of each connecting rod cap, rotate the crankshaft to verify smooth operation.

Install the connecting rod caps and the new bolts.
- Tighten the bolts in 2 stages.
- Stage 1: Tighten to 29 Nm (21 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Fig 18: Locating Connecting Rod Cap Bolts
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).

Fig 19: Installing Crankshaft TDC Timing Peg
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

NOTE: The original adjustment shims must be installed in their original position.

NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

Install the adjustment shims in their original position on the seat faces of the balancer unit.
With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.

Fig 20: Locating Balancer Unit And Shafts Reference Mark
Install the balancer unit bolts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 50 Nm (37 lb-ft).
Fig 21: Identifying Balancer Unit Bolts Tightening Sequence
Remove the Crankshaft TDC Timing Peg.

Fig 22: Installing Crankshaft TDC Timing Peg
Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
- Remove the Crankshaft TDC Timing Peg.
Fig 23: Installing Crankshaft TDC Timing Peg
NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.

NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.

NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown.

Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
- Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
- Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
- Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).
- If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For additional information, refer to the Balance Shaft Backlash procedure in this section.
Fig 24: Measuring Gear Backlash

WARNING: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Turn the crankshaft clockwise to position the No. 1 piston at TDC.
Remove the engine plug bolt.

Fig 25: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.

Fig 26: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Install the special tool.

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.

Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (15 lb-ft).
  
  Fig 27: Identifying Tightening Sequence Of Oil Pump Assembly Bolts
  Courtesy of FORD MOTOR CO.
Install a new gasket, oil pump pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 28: Locating Oil Pump Pickup Tube Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft rear main oil seal.

Fig 29: Locating Special Tool
Courtesy of FORD MOTOR CO.
Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown.
- To install, tighten to 10 Nm (89 lb-in).
  
  Fig 30: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
  Courtesy of FORD MOTOR CO.

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 traces of sealant.

Clean and inspect all mating surfaces.

NOTE: If the oil pan 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.

Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
- Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.
  
  Fig 31: Identifying Rear Oil Pan Bolts
  Courtesy of FORD MOTOR CO.
Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.

Fig 32: Using Suitable Straight Edge To Align Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
Courtesy of FORD MOTOR CO.
Install the remaining oil pan bolts.
- Tighten in the sequence shown to 20 Nm (15 lb-ft).
  
  Fig 33: Identifying Tightening Sequence Of Oil Pan Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig 34: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.

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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
Apply silicone gasket and sealant to the locations shown.

Fig 35: Identifying Silicone Gasket And Sealant Location
Courtesy of FORD MOTOR CO.
Install a new head gasket.

Fig 36: Locating Head Gasket
Courtesy of FORD MOTOR CO.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 15 Nm (11 lb-ft).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Turn 90 degrees.
- Stage 5: Turn an additional 90 degrees.
  
  Fig 37: Identifying Tightening Sequence Of Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Coat the valve tappets with clean engine oil prior to installation.

Install the valve tappets,

CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
- Stage 1: Tighten the camshaft bearing cap bolts until finger tight.
- Stage 2: Tighten to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (12 lb-ft).
  
  Fig 38: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Install the variable camshaft timing (VCT) solenoid and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 39: Locating Variable Camshaft Timing (VCT) Solenoid And Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.

Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
- The crankshaft sprocket flange must be facing away from the engine block.
  
  Fig 40: Locating Crankshaft Sprocket, Crankshaft Sprocket Diamond Washers, Oil Pump Chain And Oil Pump Sprocket
  Courtesy of FORD MOTOR CO.
Install the oil pump chain, sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 41: Locating Oil Pump Chain, Sprocket And Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain guide and the shoulder bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 42: Locating Oil Pump Chain Guide And Shoulder Bolts
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 43: Locating Oil Pump Chain Tensioner And Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 44: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Install the special tool in the slots on the rear of both camshafts.
Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

Fig 45: Locating Camshaft Sprockets And Bolts
Courtesy of FORD MOTOR CO.
Install the timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 46: Identifying Bolts And LH Timing Chain Guide
  Courtesy of FORD MOTOR CO.
Install the timing chain.

Fig 47: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Install the timing chain tensioner arm.

Fig 48: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Fig 49: Locating Timing Chain Tensioner Plunger

Courtesy of FORD MOTOR CO.

Using the edge of a vise, compress the timing chain tensioner plunger.
Using a small pick, push back and hold the ratchet mechanism.

Fig 50: Using Small Pick To Push Back
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 51: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of FORD MOTOR CO.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 52: Identifying Paper Clip Into Hole In Tensioner Housing
Courtesy of FORD MOTOR CO.
Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 53: Locating Timing Chain Tensioner Bolts And Paper Clip
  Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
- Tighten to 72 Nm (53 lb-ft).
  
  Fig 54: Identifying Camshafts Sprocket Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.

Fig 55: Locating Silicone Gasket

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following specifications:
- Tighten the 8-mm bolts to 10 Nm (89 lb-in).
- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
  
  Fig 56: Identifying Tightening Sequence Of Engine Front Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Fig 57: Installing Crankshaft Front Oil Seal Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install a new crankshaft front oil seal.

CAUTION: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Fig 58: Locating Hole In Pulley

Courtesy of FORD MOTOR CO.

Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.

CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Fig 59: Locating Bolt

Courtesy of FORD MOTOR CO.

Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
Assemble the special tools using 4 hardened washers in the locations shown.

Fig 60: Identifying Special Tools And Hardened Washers
Courtesy of FORD MOTOR CO.

CAUTION: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.

CAUTION: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees (1/4 turn).
  
  Fig 61: Locating Crankshaft Pulley Bolt And Special Tools
  Courtesy of FORD MOTOR CO.
Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

Fig 62: Aligning Crankshaft Pulley Bolt Holes
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 63: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 64: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise 1 and 3/4 turns.
Install the special tool.

Fig 65: Identifying Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Only turn the engine in the normal direction of rotation.

Fig 66: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Turn the crankshaft clockwise until the crankshaft contacts the special tool.

CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.
  
  Fig 67: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
  Courtesy of FORD MOTOR CO.
Using the special tool, check the position of the camshafts.
- If it is not possible to install the special tool, the engine valve timing must be corrected.
  
  Fig 68: Identifying Special Camshaft Tool (303-465)
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 69: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.

NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor and the 2 bolts.
- Do not tighten the bolts at this time.
  
  Fig 70: Locating CKP Sensor
  Courtesy of FORD MOTOR CO.

NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the CKP sensor with the alignment tool.
- Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
  
  Fig 71: Locating CKP Sensor Bolts And Alignment Tool
  Courtesy of FORD MOTOR CO.
Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

Fig 72: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 73: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 74: Locating Engine Plug Bolt
  Courtesy of FORD MOTOR CO.

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.

Clean the valve cover gasket surface with metal surface cleaner.

NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.

Fig 75: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the locations shown.
Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 76: Identifying Tightening Sequence Of Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.

Fig 77: Locating Oil Level Indicator

Courtesy of FORD MOTOR CO.

Install the oil level indicator.

NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.

Install the 4 coil-on-plug assemblies 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 78: Locating Coil-On-Plug Assemblies And Bolts
  Courtesy of FORD MOTOR CO.

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.

Install new fuel injector O-rings.
- Separate the fuel injectors from the fuel rail.
- Remove and discard the fuel injector O-rings.
- Install new O-rings and lubricate with clean engine oil.
- Install the fuel injectors onto the fuel rail.
  
  Fig 79: Locating Fuel Injector O-Ring Seals
  Courtesy of FORD MOTOR CO.
Install the fuel rail and injector assembly and the 2 bolts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 80: Locating Fuel Rail And Injector Assembly Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Typical wiring harness retainers shown.

Fig 81: Locating Wiring Harness Retainers

Courtesy of FORD MOTOR CO.

Position the wiring harness on the engine and attach the wiring harness retainers.
Connect the 4 fuel injector electrical connectors.

Fig 82: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the fuel supply rail insulator and attach the 2 pin-type harness retainers.

Fig 83: Locating Pin-Type Harness Retainers And Fuel Supply Rail Insulator
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor electrical connector and install the boot.

Fig 84: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector And Boot
Courtesy of FORD MOTOR CO.
Connect the 4 coil-on-plug electrical connectors.

Fig 85: Locating Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the VCT solenoid electrical connector.

Fig 86: Locating VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the camshaft position (CMP) sensor electrical connector.

Fig 87: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install a new gasket, the oil filter adapter and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 88: Locating Oil Filter Adapter Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the oil filter seal (spin on filter type) or oil filter cup O-ring seal (replaceable filter element type) with clean engine oil.

Install a new engine oil filter.
- Tighten the oil filter (spin on filter type) to 18 Nm (13 lb-ft).
- Tighten the oil filter cup (replaceable filter element type) to 33 Nm (24 lb-ft).
Using a new gasket, install the crankcase vent oil separator and the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 89: Locating Crankcase Vent Oil Separator And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.

Install the KS and the bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 90: Locating Knock Sensor Bolts
  Courtesy of FORD MOTOR CO.
Position the bypass hose on the engine and connect the bypass hose to the coolant outlet.

Fig 91: Locating Bypass Hose To Coolant Outlet
Courtesy of FORD MOTOR CO.
Connect the bypass hose to the cylinder block nipple.

Fig 92: Locating Bypass Hose To Cylinder Block Nipple
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if necessary.

Install the thermostat housing and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 93: Locating Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 94: Locating EGR Tube
  Courtesy of FORD MOTOR CO.
Position the intake manifold and connect the positive crankcase ventilation hose.

Fig 95: Locating Positive Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.
Install new gaskets, the intake manifold and the 8 bolts.
- Tighten the bolts to 18 Nm (13 lb-ft).
  
  Fig 96: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Connect the electronic throttle body electrical connector.

Fig 97: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness pin-type retainers to the intake manifold.

Fig 98: Locating Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the 2 swirl control valve electrical connectors.

Fig 99: Locating Swirl Control Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the intake manifold runner control (IMRC) actuator electrical connector.

Fig 100: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the temperature manifold actual pressure (MAP) sensor electrical connector.

Fig 101: Locating Temperature Manifold Actual Pressure (MAP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the oil pressure sender electrical connector.

Fig 102: Locating Oil Pressure Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the exhaust gas recirculation (EGR) coolant hose and electrical connector.

Fig 103: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the coolant temperature sender electrical connector.

Fig 104: Locating Coolant Temperature Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Install the catalytic converter bracket and the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 105: Locating Catalytic Converter Bracket Bolts
  Courtesy of FORD MOTOR CO.
If equipped, install the block heater.
- Tighten to 21 Nm (15 lb-ft).
  
  Fig 106: Locating Block Heater
  Courtesy of FORD MOTOR CO.
If equipped, connect the block heater electrical connector.

Fig 107: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
Install 7 new catalytic converter studs in the cylinder head.
- Tighten to 17 Nm (13 lb-ft).

CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.

CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.

NOTE: Make sure to tighten the nuts in the sequence in 2 stages.

Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).
  
  Fig 108: Identifying Catalytic Converter Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the 2 catalytic converter bracket bolts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 109: Locating Catalytic Converter Bracket Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Vehicles equipped with AIR did not require removal of the heat shield.

Install the heat shield and the 6 screws.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 110: Locating Heat Shield Screws
  Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the valve cover stud.

Fig 111: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Attach the wiring harness bracket to the valve cover stud.

Fig 112: Locating Wiring Harness Bracket
Courtesy of FORD MOTOR CO.
Connect the heated oxygen sensor (HO2S) electrical connector.

Fig 113: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Vehicles equipped with secondary air injection (AIR) have 2 catalyst monitor sensors (CMS).

Fig 114: Locating CMS Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the CMS electrical connector(s).

Vehicles with secondary air injection (AIR)

Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 115: Locating Pump Assembly Bolts
  Courtesy of FORD MOTOR CO.
Connect the AIR valve electrical connector.

Fig 116: Locating AIR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the AIR valve vacuum supply tube to the intake manifold.

Fig 117: Locating AIR Valve Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
Connect the AIR hose to the catalytic converter.

Fig 118: Locating AIR Hose
Courtesy of FORD MOTOR CO.

All vehicles

Install the generator, bolt and 2 stud bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 119: Locating Generator Bolt And Stud Bolts
  Courtesy of FORD MOTOR CO.
Connect the pin-type retainer, generator electrical connections and install the nut.
- Tighten to 6 Nm (53 lb-in).
- Install the rubber boot.
  
  Fig 120: Locating Pin-Type Retainer, Generator Electrical Connections And Install Nut
  Courtesy of FORD MOTOR CO.
Install the generator splash shield and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 121: Locating Generator Splash Shield And Nuts
  Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector and harness pin-type retainer.

Fig 122: Locating CKP Sensor Electrical Connector And Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 123: Locating Accessory Drive Belt Idler Pulley
  Courtesy of FORD MOTOR CO.

NOTE: Clean the coolant pump mating surface with metal surface cleaner.

NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.

Install the new O-ring, coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 124: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 125: Locating Coolant Pump Pulley Bolts
  Courtesy of FORD MOTOR CO.
Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 126: Locating A/C Compressor Bolts
  Courtesy of FORD MOTOR CO.
Install the A/C manifold and the bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 127: Locating A/C Manifold And Bolt
  Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connector.

Fig 128: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
Position the coolant hose on the engine and connect the coolant hose to the throttle body.

Fig 129: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Connect the lower radiator and heater hoses to the thermostat housing.

Fig 130: Locating Lower Radiator And Heater Hoses
Courtesy of FORD MOTOR CO.
Connect the KS electrical connector and the 2 harness pin-type retainers.

Fig 131: Locating KS Electrical Connector And Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Install the power steering pump and the lower bolt.
- Finger tighten the bolt.
  
  Fig 132: Locating Power Steering Pump And Lower Bolt
  Courtesy of FORD MOTOR CO.
Install the 2 upper power steering pump bolts.
- Tighten all 3 power steering bolts to 25 Nm (18 lb-ft).
  
  Fig 133: Locating Upper Power Steering Pump Bolts
  Courtesy of FORD MOTOR CO.
Connect the power steering pressure (PSP) switch electrical connector.

Fig 134: Locating Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
On late build engines, install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 135: Locating Accessory Drive Belt Tensioner Bolts
  Courtesy of FORD MOTOR CO.
On early build vehicles, install the shield, pin-type retainer, tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 136: Locating Shield, Pin-Type Retainer, Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the coolant pump pulley.
Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.
1. On early build engines, use the pulley bolt to rotate the tensioner.
2. On late build engines, use the hex feature to rotate the tensioner.
  
  Fig 137: Using Pulley Bolt And Hex Feature To Rotate Tensioner
  Courtesy of FORD MOTOR CO.
Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.

Vehicles with automatic transaxle

Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (50 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
  
  Fig 138: Identifying Tightening Sequence Of Flexplate Bolts
  Courtesy of FORD MOTOR CO.

Vehicles with manual transaxle

Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (50 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
  
  Fig 139: Identifying Flexplate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the starter motor isolator.

Fig 140: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
Lubricate the transaxle input shaft pilot bearing with front axle grease.

Fig 141: Locating Front Axle Grease Area
Courtesy of FORD MOTOR CO.
Using the special tool, position the clutch disc on the flywheel.

Fig 142: Locating Special Tool And Clutch Disc
Courtesy of FORD MOTOR CO.

NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal.

Position the clutch pressure plate and install the 6 bolts.
- Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.