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Engine Mechanical: Mechanical: Engine-3.8L: Assembly: Engine

Fig 1: Identifying Special Tools
G01623857Courtesy of FORD MOTOR CO.
Fig 2: Identifying Material Specifications
G01623858Courtesy of FORD MOTOR CO.
CAUTION: The moving components must be lubricated with clean engine oil before assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed holes.
  1. If necessary, install the following:
    1. the cylinder block dowels.
    2. the oil gallery plugs.
    3. the water jacket plugs.
      Fig 3: Installing Cylinder Block Dowels, Oil Gallery Plugs And Water Jacket Plugs
      G01623859Courtesy of FORD MOTOR CO.
  2. If equipped, install the engine coolant heater. For additional information refer to ENGINE COOLING .
  3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings.
    Fig 4: Installing Engine Dynamic Balance Shaft Bearings
    G01623860Courtesy of FORD MOTOR CO.
  4. Using the camshaft bearing service set, install the camshaft bearings.
    Fig 5: Installing Camshaft Bearings
    G01623861Courtesy of FORD MOTOR CO.
  5. Install the following:
    1. the engine dynamic balance shaft bearing cover.
    2. the camshaft bearing cover.
      Fig 6: Installing Engine Dynamic Balance Shaft Bearing Cover And Camshaft Bearing Cover
      G01623862Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
    Fig 7: Installing Camshaft And Camshaft Spacer
    G01623863Courtesy of FORD MOTOR CO.
  6. Install the camshaft and the camshaft spacer.
  7. Install the camshaft thrust plate.
    1. Position the camshaft thrust plate.
    2. Install the bolts.
      Fig 8: Installing Camshaft Thrust Plate
      G01623864Courtesy of FORD MOTOR CO.
  8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
    Fig 9: Aligning Timing Marks
    G01623865Courtesy of FORD MOTOR CO.
    9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.
    Fig 10: Identifying Tightening Torque Of Balance Shaft Drive Gear Bolts
    G01623866Courtesy of FORD MOTOR CO.
  9. Install the bolts.
    10. CAUTION: Make sure the components are installed in the correct location.
    NOTE: Lubricate the crankshaft main bearings prior to installation.
    Fig 11: Installing Crankshaft Upper Main Bearings And Crankshaft Upper Thrust Main Bearing
    G01623867Courtesy of FORD MOTOR CO.
  10. Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing.
    11. CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft
    Fig 12: View Of Crankshaft
    G01623868Courtesy of FORD MOTOR CO.
    CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  11. Position the crankshaft.
    12. NOTE: If the rear main bearing cap is not secured within four minutes, 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 13: Identifying Rear Main Bearing Cap Sealing Area
    G01623869Courtesy of FORD MOTOR CO.
  12. Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.
  13. Install the main bearing caps. Tighten the bolts in two stages:
    • Stage 1: Tighten to 50 Nm (37 lb-ft).
    • Stage 2: Rotate an additional 120 degrees.
      Fig 14: Installing Main Bearing Caps
      G01623870Courtesy of FORD MOTOR CO.
  14. Compress the piston rings.
    Fig 15: Compressing Piston Rings
    G01623871Courtesy of FORD MOTOR CO.
    15. CAUTION: Inspect the piston clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod.
    Fig 16: Identifying Arrow On Piston Face For Installing Piston
    G01623872Courtesy of FORD MOTOR CO.
  15. Install the piston with the arrow on the piston face pointing toward the front of the engine.
    16. CAUTION: Inspect the connecting rod bearing clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    CAUTION: The connecting rod cap will fit only one way.
    Fig 17: Positioning Connecting Lower Rod Bearing And Connecting Rod Cap On Connecting Rod And Crankshaft Journal
    G01623873Courtesy of FORD MOTOR CO.
  16. Position the connecting lower rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.
  17. Install the rod caps. Tighten the bolts in three stages:
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 45 Nm (33 lb-ft).
    • Stage 3: Tighten an additional 105 degrees.
      Fig 18: Tightening Rod Caps Bolts
      G01623874Courtesy of FORD MOTOR CO.
  18. Install the remaining pistons and the connecting rods.
  19. Install the oil pan bridge and baffle assembly.
    Fig 19: Installing Oil Pan Bridge And Baffle Assembly
    G01623875Courtesy of FORD MOTOR CO.
  20. Using a new gasket, install the oil pump screen cover and tube.
    Fig 20: Installing Oil Pump Screen Cover And Tube
    G01623876Courtesy of FORD MOTOR CO.
  21. Install the timing chain tensioner.
    1. Position the timing chain tensioner.
    2. Install the bolts.
      Fig 21: Positioning Timing Chain Tensioner
      G01623877Courtesy of FORD MOTOR CO.
  22. Retract the tensioner pad retracting mechanism.
    1. Compress the tensioner pad retracting mechanism.
    2. Insert a retaining pin.
      Fig 22: Retracting Tensioner Pad Retracting Mechanism
      G01623878Courtesy of FORD MOTOR CO.
  23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position.
    Fig 23: Locating Crankshaft Keyway
    G01623879Courtesy of FORD MOTOR CO.
  24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
    Fig 24: Locating Camshaft Sprocket
    G01623880Courtesy of FORD MOTOR CO.
  25. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
    Fig 25: Installing Timing Chain, Camshaft Sprocket And Crankshaft Sprocket As An Assembly
    G01623881Courtesy of FORD MOTOR CO.
  26. Make sure the timing marks and the keyways are aligned.
    Fig 26: Aligning Timing Marks And Keyways
    G01623882Courtesy of FORD MOTOR CO.
  27. Install the camshaft position sensor drive gear and retaining bolt.
    Fig 27: Installing Camshaft Position Sensor Drive Gear And Retaining Bolt
    G01623883Courtesy of FORD MOTOR CO.
    28. CAUTION: The components removed should be marked for location. Make sure the used parts are installed in the correct location.
    Fig 28: Removing Retaining Pin
    G01623884Courtesy of FORD MOTOR CO.
  28. Remove the retaining pin.
    29. NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
    Fig 29: Installing RH And LH Cylinder Heads
    G01623885Courtesy of FORD MOTOR CO.
  29. Using new gaskets, install the RH and the LH cylinder heads.
    30. CAUTION: Always use new bolts
    NOTE: Lubricate the bolts with clean engine oil prior to installation.
  30. Position the new bolts.
    1. Position the new long bolts.
    2. Position the new short bolts.
      Fig 30: Locating Cylinder Head Bolts
      G01623886Courtesy of FORD MOTOR CO.
  31. Tighten the bolts in three stages in the sequence shown:
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 40 Nm (30 lb-ft).
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
      Fig 31: Identifying Tightening Sequence Of Bolts
      G01623887Courtesy of FORD MOTOR CO.
    32. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and tightened prior to working on the next bolt in the sequence.
  32. Tighten the bolts in four stages in the sequence shown: short bolts numbered 2, 4, 6 and 8:
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten an additional 180 degrees. Long bolts numbered 1, 3, 5 and 7
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
      Fig 32: Identifying Tightening Sequence Of Bolts
      G01623888Courtesy of FORD MOTOR CO.
    33. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.
  33. Install the valve tappets.
    • Install the valve tappets.
    • Install the tappet guide plates and retainers.
    • Install the bolts.
      Fig 33: Installing Valve Tappets
      G01623889Courtesy of FORD MOTOR CO.
    34. NOTE: Lubricate the push rods with clean engine oil prior to installation.
    Fig 34: Installing Push Rods
    G01623890Courtesy of FORD MOTOR CO.
  34. Install the 12 push rods.
  35. Install the 12 rocker arms. For additional information, refer to ROCKER ARM .
    36. NOTE: Use pipe sealant with Teflon® on studs No. 4 and 6, and bolt No. 12.
  36. Using a new gasket, install the engine front cover. Tighten the nuts and the bolts in the sequence shown.
    • Install a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb-in).
    • Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lb-in).
    • Using a new gasket, install the water pump.
    • Tighten bolt No. 12 to 10 Nm (89 lb-in).

      All other nuts and bolts are to be tightened to 28 Nm (21 lb-ft).

      Fig 35: Identifying Tightening Sequence Of Engine Front Cover Bolts
      G01623891Courtesy of FORD MOTOR CO.
    37. NOTE: Lubricate the parts with clean engine oil before assembly.
    Fig 36: Installing Front Crankshaft Seal
    G01623892Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the front crankshaft seal.
  38. Install the crankshaft position sensor.
    Fig 37: Installing Crankshaft Position Sensor
    G01623893Courtesy of FORD MOTOR CO.
  39. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper. Using the special tool, position and install the crankshaft damper.
    Fig 38: Installing Crankshaft Damper
    G01623894Courtesy of FORD MOTOR CO.
  40. Install the crankshaft pulley bolt.
    Fig 39: Identifying Tightening Torque Of Crankshaft Pulley Bolt
    G01623895Courtesy of FORD MOTOR CO.
  41. Install the camshaft synchronizer. For additional information, refer to REMOVAL & INSTALLATION .
  42. Install the water pump pulley and the retaining bolts.
    Fig 40: Installing Water Pump Pulley And Retaining Bolts
    G01623896Courtesy of FORD MOTOR CO.
    43. NOTE: If the oil pan is not secured within four minutes, 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  43. Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
    1. Apply silicone gasket and sealant to the rear main bearing cap.
    2. Install the oil pan rear seal.
    3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surface.
      Fig 41: Identifying Oil Pan Sealing Area For Applying Sealant
      G01623897Courtesy of FORD MOTOR CO.
  44. Tighten the oil pan bolts in the sequence shown.
    Fig 42: Identifying Tightening Sequence Of Oil Pan Bolts
    G01623898Courtesy of FORD MOTOR CO.
  45. Install the RH valve cover.
    Fig 43: Installing RH Valve Cover
    G01623899Courtesy of FORD MOTOR CO.
  46. Install the LH valve cover.
    Fig 44: Installing LH Valve Cover
    G01623900Courtesy of FORD MOTOR CO.
  47. Install the generator mounting bracket.
    Fig 45: Installing Generator Mounting Bracket
    G01623901Courtesy of FORD MOTOR CO.
  48. Install the power steering pump bracket.
    Fig 46: Installing Power Steering Pump Bracket
    G01623902Courtesy of FORD MOTOR CO.
  49. Using the special tool, install the power steering pump pulley.
    Fig 47: Installing Power Steering Pump Pulley
    G01623903Courtesy of FORD MOTOR CO.
  50. Install the A/C compressor bracket and the bolts.
    Fig 48: Installing A/C Compressor Bracket And Bolts
    G01623904Courtesy of FORD MOTOR CO.
  51. Install the accessory drive belt.
    Fig 49: Installing Accessory Drive Belt
    G01623905Courtesy of FORD MOTOR CO.
  52. Refer to the illustration for intake manifold sealing components.
    Fig 50: Identifying Intake Manifold Components For Applying Sealant
    G01623906Courtesy of FORD MOTOR CO.
    53. NOTE: If the lower intake manifold is not secured within four minutes, 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  53. Install the lower intake manifold front and rear end seals.
    1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
    2. Install the lower intake manifold front and rear end seals.
      Fig 51: Installing Lower Intake Manifold Front And Rear End Seals
      G01623907Courtesy of FORD MOTOR CO.
  54. Install the intake manifold gaskets.
    Fig 52: Installing Intake Manifold Gaskets
    G01623908Courtesy of FORD MOTOR CO.
    55. NOTE: If the lower intake manifold is not secured within four minutes, 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 four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  55. Position the lower intake manifold.
    1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.
    2. Position the lower intake manifold.
      Fig 53: Positioning Lower Intake Manifold
      G01623909Courtesy of FORD MOTOR CO.
  56. Install the lower intake manifold bolts.
    • Install the six long bolts.
    • Install the eight short bolts.
      Fig 54: Installing Lower Intake Manifold Bolts
      G01623910Courtesy of FORD MOTOR CO.
  57. Tighten the bolts in two stages in the sequence shown.
    1. Stage 1: Tighten to 5 Nm (44 lb-in).
    2. Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 55: Identifying Tightening Sequence Of Lower Intake Manifold Bolts
      G01623911Courtesy of FORD MOTOR CO.
  58. Install the heater water outlet tube.
    Fig 56: Installing Heater Water Outlet Tube
    G01623912Courtesy of FORD MOTOR CO.
  59. Install the stud bolt.
    Fig 57: Installing Stud Bolt
    G01623913Courtesy of FORD MOTOR CO.
  60. Position the engine wire harness.
    Fig 58: Installing Engine Wire Harness
    G01623914Courtesy of FORD MOTOR CO.
  61. Connect the crankshaft position sensor electrical connector.
    Fig 59: Connecting Crankshaft Position Sensor Electrical Connector
    G01623915Courtesy of FORD MOTOR CO.
  62. Install the pin-type retainer.
    Fig 60: Installing Pin-Type Retainer
    G01623916Courtesy of FORD MOTOR CO.
  63. Connect the engine oil pressure sender electrical connector.
    Fig 61: Connecting Engine Oil Pressure Sender Electrical Connector
    G01623917Courtesy of FORD MOTOR CO.
  64. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 62: Connecting Camshaft Position (CMP) Sensor Electrical Connector
    G01623918Courtesy of FORD MOTOR CO.
  65. Connect the cylinder head temperature (CHT) sensor.
    Fig 63: Connecting Cylinder Head Temperature (CHT) Sensor
    G01623919Courtesy of FORD MOTOR CO.
  66. Install the fuel injectors and the fuel injection supply manifold as an assembly. For additional information, refer to REMOVAL & INSTALLATION .
  67. Install a new upper intake manifold gasket.
    Fig 64: Installing Upper Intake Manifold Gasket
    G01623920Courtesy of FORD MOTOR CO.
    68. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.
  68. Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Rotate an additional 90 degrees.
      Fig 65: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
      G01623921Courtesy of FORD MOTOR CO.
  69. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connections.
    Fig 66: Connecting Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid Electrical And Vacuum Connections
    G01623922Courtesy of FORD MOTOR CO.
  70. Connect the differential pressure feedback EGR system electrical and vacuum connections.
    Fig 67: Connecting Differential Pressure Feedback EGR System Electrical And Vacuum Connections
    G01623923Courtesy of FORD MOTOR CO.
  71. Connect the vacuum hoses.
    Fig 68: Connecting Vacuum Hoses
    G01623924Courtesy of FORD MOTOR CO.
  72. Install the positive crankcase ventilation (PCV) tube.
    Fig 69: Installing Positive Crankcase Ventilation (PCV) Tube
    G01623925Courtesy of FORD MOTOR CO.
  73. Connect the ignition coil and the radio interference capacitor electrical connectors.
    Fig 70: Connecting Ignition Coil And Radio Interference Capacitor Electrical Connectors
    G01623926Courtesy of FORD MOTOR CO.
  74. Position and connect the LH spark plug wires.
    Fig 71: Connecting LH Spark Plug Wires
    G01623927Courtesy of FORD MOTOR CO.
  75. Position and connect the RH spark plug wires.
    Fig 72: Connecting RH Spark Plug Wires
    G01623928Courtesy of FORD MOTOR CO.
  76. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
    Fig 73: Connecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
    G01623929Courtesy of FORD MOTOR CO.
  77. Install the RH exhaust manifold.
    • Install a new exhaust manifold gasket.
    • Install the exhaust manifold.
    • Tighten the nuts in the sequence shown.
      Fig 74: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
      G01623930Courtesy of FORD MOTOR CO.
  78. Install the exhaust gas recirculation (EGR) tube.
    Fig 75: Installing Exhaust Gas Recirculation (EGR) Tube
    G01623931Courtesy of FORD MOTOR CO.
  79. Connect the EGR valve nut.
    Fig 76: Connecting EGR Valve Nut
    G01623932Courtesy of FORD MOTOR CO.
  80. Using a new gasket, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
    Fig 77: Identifying Tightening Sequence Of LH Exhaust Manifold Bolts
    G01623933Courtesy of FORD MOTOR CO.
    81. NOTE: Install a new O-ring seal
    Fig 78: Installing Oil Level Indicator And Tube And Retaining Bolt
    G01623934Courtesy of FORD MOTOR CO.
  81. Install the oil level indicator and tube and retaining bolt.
  82. Install the special tool.
    Fig 79: Installing Special Tool
    G01623935Courtesy of FORD MOTOR CO.
  83. Install the special tool.
    Fig 80: Installing Special Tool
    G01623936Courtesy of FORD MOTOR CO.
  84. Install the RH engine support insulator.
    Fig 81: Installing RH Engine Support Insulator
    G01623937Courtesy of FORD MOTOR CO.
  85. Install the LH engine support insulator.
    Fig 82: Installing LH Engine Support Insulator
    G01623938Courtesy of FORD MOTOR CO.
  86. Remove the engine from the stand.
    87. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
    Fig 83: Assembling Special Tools And Crankshaft Rear Seal
    G01623939Courtesy of FORD MOTOR CO.
  87. Assemble the special tools and the crankshaft rear seal.
  88. Install the special tools on the rear of the crankshaft.
    Fig 84: Installing Special Tools On Rear Of Crankshaft
    G01623940Courtesy of FORD MOTOR CO.
  89. Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303-561) contacts the engine block.
    Fig 85: Tightening Center Jack Screw
    G01623941Courtesy of FORD MOTOR CO.
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