Cylinder Heads

SPECIAL TOOLS DESCRIPTION

	Installer, Crankshaft Front Oil Seal 303-646
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Aligner, Camshaft 303-530
	Tensioner, Timing Chain 303-532
	Alignment Gauge, Crankshaft 303-645
	Remover/Installer, Crankshaft Rear Oil Seal 303-647
	Adapter for 204-185 204-208 (T95T-5310-AR2)
	Lifting Brackets, Engine 303-050 (T70P-6000)
	Spreader Bar 303-D089 (D93P-6001-A3)

MATERIAL SPECIFICATIONS

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

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.

RH side

Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
Install a new gasket and position the RH cylinder head on the engine.

Fig 1: Positioning Cylinder Head On Block
Courtesy of FORD MOTOR CO.

NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always use new bolts.

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.
  
  Fig 2: Identifying RH Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the 2 end bolts and tighten in 2 stages.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 3: Identifying RH Cylinder Head End Bolts
  Courtesy of FORD MOTOR CO.

LH side

Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
Install a new gasket and position the LH cylinder head on the engine.

Fig 4: Positioning Cylinder Head On Block
Courtesy of FORD MOTOR CO.
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 5: Tightening LH Head Bolts Sequence
  Courtesy of FORD MOTOR CO.
Install the 2 end bolts and tighten in 2 stages.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 6: Installing End Bolts
  Courtesy of FORD MOTOR CO.

Both sides

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

Fig 7: Installing Valve Tappets And Shims In Original Locations

Courtesy of FORD MOTOR CO.

Install the valve tappets and shims in their original locations.

RH side

NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.

Fig 8: Locating RH Camshafts On Camshaft Journals

Courtesy of FORD MOTOR CO.

Position the RH camshafts on the camshaft journals.

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.

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.
    
    Fig 9: Identifying Bearing Cap Bolts Tightening Sequence
    Courtesy of FORD MOTOR CO.

LH side

NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.

Fig 10: Positioning LH Camshafts On Camshaft Journals

Courtesy of FORD MOTOR CO.

Position the LH camshafts on the camshaft journals.

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.

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.
    
    Fig 11: Identifying Bolts Tightening Sequence
    Courtesy of FORD MOTOR CO.

Both sides

CAUTION: If any components are installed new, the engine must be reshimmed or engine damage can occur.

Fig 12: Checking Clearance Using Feeler Gauge

Courtesy of FORD MOTOR CO.

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.
If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to VALVE CLEARANCE ADJUSTMENT in this article.

NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.

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.
  
  Fig 13: Installing Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: LR shown, RH similar.

Fig 14: Positioning Of Camshafts That Flats Of Camshafts Facing Upward

Courtesy of FORD MOTOR CO.

Position all of the camshafts so the flats of the camshafts are facing upward.
Install the LH secondary timing chain tensioner and 2 bolts.
- Tighten to 11 Nm (8 lb-ft).
Install the LH variable cam timing (VCT) unit, exhaust camshaft sprocket and timing chain as an assembly.

Fig 15: Installing LH Variable Cam Timing (VCT) Unit, Exhaust Camshaft Sprocket And Timing Chain
Courtesy of FORD MOTOR CO.
Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.

Fig 16: Installing LH VCT Unit And Exhaust Camshaft Sprocket Bolts Finger-Tight
Courtesy of FORD MOTOR CO.
Remove the locking pin from the LH secondary timing chain tensioner.

Fig 17: Locating Locking Pin For LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Install the RH secondary timing chain tensioner and 2 bolts.
- Tighten to 11 Nm (8 lb-ft).
Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.

Fig 18: Identifying RH VCT Unit
Courtesy of FORD MOTOR CO.
Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.

Fig 19: Identifying RH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain
Courtesy of FORD MOTOR CO.
Remove the locking pin from the RH secondary timing chain tensioner.

Fig 20: Locating Locking Pin For RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
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 21: Pushing Lever Down And Installing Drill Rod To Lock Piston
  Courtesy of FORD MOTOR CO.

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 22: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool on the LH head.
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 23: Identifying LH Timing Chain And Crankshaft Gear
  Courtesy of FORD MOTOR CO.
Install the LH timing chain guide and bolt.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 24: Identifying LH Timing Chain Guide And Bolt
  Courtesy of FORD MOTOR CO.
Install the LH timing chain tensioner arm and nut.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 25: Identifying LH Timing Chain Tensioner Arm And Nut
  Courtesy of FORD MOTOR CO.
Install the LH timing chain tensioner.
- Install the timing chain tensioner and bolts, and remove the drill rod.
  
  Fig 26: Installing Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.

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.

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.
  
  Fig 27: Tightening LH Exhaust Camshaft Sprocket And Variable Camshaft Timing (VCT) Unit Bolts
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 28: Identifying Special Tool
Courtesy of FORD MOTOR CO.

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 downward evenly until it is fully seated on the camshaft flats.

Fig 29: Identifying Special Tool On RH Cylinder Head

Courtesy of FORD MOTOR CO.

Install the special tool on the right cylinder head.
Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.

Fig 30: Identifying RH Primary Timing Chain
Courtesy of FORD MOTOR CO.
Install the RH timing chain guide and bolt.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 31: Identifying Bolt And RH Timing Chain Guide
  Courtesy of FORD MOTOR CO.
Install the RH timing chain tensioner arm.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 32: Identifying RH Timing Chain Tensioner Arm
  Courtesy of FORD MOTOR CO.
Install the RH timing chain tensioner.
- Install the timing chain tensioner and bolts, and remove the drill rod.
  
  Fig 33: Installing Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.

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.

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.
  
  Fig 34: Tightening RH Exhaust Camshaft Sprocket And VCT Unit Bolts
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 35: Identifying Special Tool On RH Cylinder Head
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 36: Identifying Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the VCT bush carrier seals with clean engine oil.

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).
  
  Fig 37: Inserting Bush Carrier Into VCT Unit
  Courtesy of FORD MOTOR CO.
Install new engine front cover gaskets.

Fig 38: Installing New Engine Front Cover Gaskets
Courtesy of FORD MOTOR CO.

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 39: Locating Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in the 8 places shown.
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 40: Identifying Bolts Tightening Sequence
    Courtesy of FORD MOTOR CO.

NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.

Fig 41: Installing Front Crankshaft Seal

Courtesy of FORD MOTOR CO.

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

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 42: Applying Bead Of Silicone Gasket And Sealant To Keyway

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant to the keyway.
Using the special tool, install the crankshaft pulley.

Fig 43: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
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 44: Identifying Special Tool To Hold Pulley
  Courtesy of FORD MOTOR CO.

LH side

Install the 8 new LH exhaust manifold studs.
- Tighten to 19 Nm (14 lb-ft).
Install the new LH exhaust manifold gasket and the heat shield stud bolt.
- Tighten to 50 Nm (37 lb-ft).
  
  Fig 45: Locating LH Exhaust Manifold Heat Shield Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold and the 8 new nuts.
- Tighten the nuts to 25 Nm (18 lb-ft) in the sequence shown.
  
  Fig 46: Identifying Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold heat shield and 4 bolts.
- Tighten to 3 Nm (27 lb-in).
  
  Fig 47: Identifying Bolts And Exhaust Manifold Heat Shield
  Courtesy of FORD MOTOR CO.

RH side

Install the 8 new RH exhaust manifold studs.
- Tighten to 19 Nm (14 lb-ft).
Install the new RH exhaust manifold gasket and the heat shield stud bolt.
- Tighten to 50 Nm (37 lb-ft).
  
  Fig 48: Installing RH Exhaust Manifold Gasket And Heat Shield Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold and the 8 new nuts.
- Tighten the nuts to 25 Nm (18 lb-ft) in the sequence shown.
  
  Fig 49: Identifying Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold heat shield and 4 bolts.
- Tighten to 3 Nm (27 lb-in).
  
  Fig 50: Installing RH Exhaust Manifold Heat Shield And Bolts
  Courtesy of FORD MOTOR CO.
Install a new gasket, EGR tube and 2 nuts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 51: Locating Nuts And EGR Tube
  Courtesy of FORD MOTOR CO.

Both sides

NOTE: RH shown, LH similar.

Fig 52: Installing Valve Cover Gaskets

Courtesy of FORD MOTOR CO.

Install new valve cover gaskets.

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 53: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Apply 4 beads of silicone gasket and sealant as shown.
Install the LH valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 54: Identifying Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the RH valve cover.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 55: Identifying Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install new intake manifold gaskets.

Fig 56: Intake Manifold Gasket Locations
Courtesy of FORD MOTOR CO.
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 57: Identifying Bolts Loosening/Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install a new gasket, the throttle body adapter and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 58: Installing Gasket, Throttle Body Adapter And Bolts
  Courtesy of FORD MOTOR CO.
Install new O-ring seals, the coolant bypass housing and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
Connect the 2 throttle body coolant hoses.

Fig 59: Locating Throttle Body Coolant Hoses
Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install the 2 radio interference ignition capacitors and the 2 nuts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 60: Identifying Radio Interference Ignition Capacitors Mounting Bracket And Nuts
  Courtesy of FORD MOTOR CO.
Connect the exhaust manifold tube to the exhaust gas recirculation (EGR) system module.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 61: Connecting Exhaust Manifold Tube To Exhaust Gas Recirculation (EGR) System Module
  Courtesy of FORD MOTOR CO.
Install the crankcase vent tube.

Fig 62: Identifying Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
Install the 8 ignition coils and bolts.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 63: Identifying Bolts And Ignition Coils
  Courtesy of FORD MOTOR CO.

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.

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).
  
  Fig 64: Locating Nut And Oil Level Indicator Tube
  Courtesy of FORD MOTOR CO.
Install the crankshaft position (CKP) sensor and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 65: Identifying Bolt And CKP Sensor
  Courtesy of FORD MOTOR CO.
Position the engine wiring harness onto the engine.
Attach the heated oxygen sensor (HO2S) electrical connectors onto the brackets.

Fig 66: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Brackets
Courtesy of FORD MOTOR CO.
Connect the generator electrical connector and wiring harness retainers.

Fig 67: Identifying Generator Electrical Connector, Wiring Harness And Retainers
Courtesy of FORD MOTOR CO.
Connect the wiring harness retainers to the RH valve cover.

Fig 68: Locating Wiring Harness Retainers At RH Valve Cover
Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector and wiring harness retainers.

Fig 69: Identifying CKP Sensor Electrical Connector And Wiring Harness
Courtesy of FORD MOTOR CO.
Attach the wiring harness onto the front cover.

Fig 70: Attaching Wiring Harness Onto Front Cover
Courtesy of FORD MOTOR CO.
Connect the wiring harness retainers to the LH valve cover.

Fig 71: Locating Wiring Harness Retainers At LH Valve Cover
Courtesy of FORD MOTOR CO.
Install the power steering bracket and 5 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 72: Identifying Power Steering Bracket And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 73: Locating VCT Sensor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the VCT sensor electrical connectors.
Connect the KS and CMP sensor electrical connectors.
- Attach the pin-type retainers.
  
  Fig 74: Locating KS And CMP Sensor Electrical Connectors
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 75: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the 8 fuel injector and the 2 radio interference capacitor electrical connectors.

NOTE: RH shown, LH similar.

Install the 2 engine appearance cover brackets and the 4 nuts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 76: Identifying Engine Appearance Cover Brackets And Nuts
  Courtesy of FORD MOTOR CO.
Attach the vacuum hose retainers onto the LH engine appearance cover support bracket.

Fig 77: Attaching Vacuum Hose Retainers Onto LH Engine Appearance Cover Support Bracket
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 78: Identifying Engine Wiring Harness

Courtesy of FORD MOTOR CO.

Connect the engine wiring harness retainers to the engine appearance cover support brackets.
Connect the 8 ignition coil electrical connectors.

Fig 79: Identifying Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: Remove all dirt and moisture from the valve cover before applying silicone sealer.

Fig 80: Applying Bead Of Silicone Sealer In Notch Of Valve Cover

Courtesy of FORD MOTOR CO.

Lift up the wiring harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.

Fig 81: Applying Additional Sealer To Surround Wire Harness And Notch
Courtesy of FORD MOTOR CO.
Install the ignition coil covers.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 82: Installing Ignition Coil Covers
  Courtesy of FORD MOTOR CO.
Install the vacuum harness.

Fig 83: Identifying Vacuum Harness
Courtesy of FORD MOTOR CO.
Connect the coolant vent hose to the coolant outlet.

Fig 84: Identifying Coolant Vent Hose To Coolant Outlet
Courtesy of FORD MOTOR CO.
Connect the EGR system module electrical connector.

Fig 85: Connecting EGR System Module Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the fuel rail temperature sensor electrical connector.

Fig 86: Locating Fuel Rail Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the evaporative emissions (EVAP) tube.

Fig 87: Locating Evaporative Emissions Tube
Courtesy of FORD MOTOR CO.
Connect the electronic throttle body electrical connector.

Fig 88: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the fuel pressure sensor electrical connector.

Fig 89: Locating Fuel Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the throttle position (TP) sensor electrical connector.

Fig 90: Identifying Throttle Position (TP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Using the special tool, install the coolant pump pulley and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 91: Installing Coolant Pump Pulley And Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley and bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 92: Installing Accessory Drive Belt Idler Pulley And Bolt
  Courtesy of FORD MOTOR CO.
Remove the bolt and the accessory drive belt tensioner.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 93: Locating Bolt And Accessory Drive Belt Tensioner
  Courtesy of FORD MOTOR CO.

CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

NOTE: Lubricate the gasket with clean engine oil.

Position the new oil cooler, the 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).
  
  Fig 94: Rotating Cooler Clockwise That Locating Pin Hits Stop
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the gasket with clean engine oil.

Install a new oil filter and tighten until the seal makes contact.
- Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
Connect the oil pressure and oil temperature sensor electrical connectors.

Fig 95: Locating Oil Pressure And Oil Temperature Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the engine block drain plug.
- Tighten to 50 Nm (37 lb-ft).
Install the special tool.

Fig 96: Installing Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 97: Installing Special Tool
Courtesy of FORD MOTOR CO.
Install the engine lifting equipment and remove the engine from the stand.