Engine (Except Block)

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane 014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
Courtesy of FORD MOTOR CO.	Timing Peg, Crankshaft 303-507
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Adapter for 205-126 (205-072-02)
Courtesy of FORD MOTOR CO.	Installer, Front Oil Seal 303-096 (T74P-6150-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1)
Courtesy of FORD MOTOR CO.	Aligner, Clutch Disc 308-006 (T71P-7137-H)

MATERIALS

Item	Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Motorcraft Metal Surface Cleaner ZC-21	WSE-M5B392-A
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Silicone Gasket Remover ZC-30	-
Motorcraft Metal Surface Prep ZC-31	-
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)	WSS-M97B51-A1
High-Temp 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A	ESA-M1C198-A

Fig 1: Identifying Engine Components - Lower Engine Block (View1)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Lower Engine Block Components (View 2)

ITEM DESCRIPTION

Item	Part Number	Description
1	6161	Piston oil control spacer (4 required)
2	6150	Piston compression upper ring (4 required)
3	6152	Piston compression lower ring (4 required)
4	6159	Piston oil control upper segment ring (4 required)
5	6159	Piston oil control lower segment ring (4 required)
6	6140	Piston pin retainer (8 required)
7	6135	Piston pin (4 required)
8	6200	Connecting rod (4 required)
9	6211	Connecting rod upper bearing (4 required)
10	6110	Piston (4 required)
11	6211	Connecting rod lower bearing (4 required)
12	6210	Connecting rod cap (4 required)
13	6010	Cylinder block
14	6333	Cylinder block crankshaft main bearing (5 required)
15	6303	Crankshaft
16	6333	Crankshaft main bearing beam bearing (5 required)
17	6F098	Main bearing beam
18	6K360	Balance shaft assembly

Fig 3: Identifying Engine Components - Front Engine Block

Courtesy of FORD MOTOR CO.

Fig 4: Identifying Engine Components - Cylinder Head

Courtesy of FORD MOTOR CO.

Fig 5: Identifying Engine Components - Intake Manifold

Courtesy of FORD MOTOR CO.

CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

All engines

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 6: 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 7: 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 8: 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 9: 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 10: Identifying Crankshaft Block Main Bearing Bore Diameter
Using the chart, select the crankshaft main bearings.

Fig 11: 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 12: 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 13: 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 14: 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 15: 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 16: Locating Crankshaft Main Bearings
Lubricate journals on the crankshaft with clean engine oil.
Position the crankshaft in the cylinder block.

Fig 17: Locating Crankshaft
Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.

Fig 18: 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 19: 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 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 26: Identifying Balancer Unit Bolts Tightening Sequence
Remove the Crankshaft TDC Timing Peg.

Fig 27: 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 28: 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 29: Measuring Gear Backlash

All vehicles
Install the intermediate shaft bearing bracket and 3 bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 30: Locating Intermediate Shaft Bearing Bracket And Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: 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 31: 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 32: 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 33: Identifying Oil Pump Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install a new oil pump pickup tube gasket and the pickup tube.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 34: Locating Oil Pump Pickup Tube Gasket And Pickup Tube
  Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft rear main oil seal.

Fig 35: Identifying Special Tool (303-328)
Courtesy of FORD MOTOR CO.
Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 36: Identifying Crankshaft Rear Main Oil Seal Bolts Tightening Sequence
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.

Fig 37: Identifying Rear Oil Pan Bolts

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.

Fig 38: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
Courtesy of FORD MOTOR CO.
Install the remaining 13 oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb-ft).

Fig 39: Identifying Tightening Sequence Of Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig 40: 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 41: Identifying Silicone Gasket And Sealant Location
Courtesy of FORD MOTOR CO.
Install a new head gasket.

Fig 42: 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 5 Nm (44 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 43: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

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 disassembly 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 bolts in the sequence shown in 3 stages.
- Stage 1: Tighten one turn at a time until tight.
- Stage 2: Tighten to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (12 lb-ft).
  
  Fig 44: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  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 45: Locating Crankshaft Sprocket Flange
  Courtesy of FORD MOTOR CO.
Install the oil pump chain, sprocket and bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 46: Locating Oil Pump Chain, Sprocket And Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump chain guide and the 3 shoulder bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 47: Locating Oil Pump Chain Guide And Shoulder Bolts
  Courtesy of FORD MOTOR CO.
Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 48: Locating Oil Pump Chain Tensioner
  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 49: 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 50: Locating Camshaft Sprocket Bolts
Courtesy of FORD MOTOR CO.
Install the LH timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 51: Identifying Bolts And LH Timing Chain Guide
  Courtesy of FORD MOTOR CO.
Install the timing chain.

Fig 52: View Of Timing Chain
Courtesy of FORD MOTOR CO.
Install the RH timing chain guide.

Fig 53: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.

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

Fig 54: 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 55: Locating Small Pick
Courtesy of FORD MOTOR CO.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 56: 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 57: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And Plunger
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 58: 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.

Fig 59: Locating Camshaft Sprocket Bolts

Courtesy of FORD MOTOR CO.

Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft sprocket bolts to 72 Nm (53 lb-ft).

CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks 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 60: Locating Silicone Gasket

Courtesy of FORD MOTOR CO.

Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 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 61: Locating Engine Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

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

NOTE: Lubricate the oil seal with clean engine oil.

Fig 62: 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 63: Locating Hole In Crankshaft 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 64: 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 65: Assembling Special Tools (205-072-02 And 205-126)
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 66: Identifying Special Tools Assembly (205-072-02/205-126) And Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

Fig 67: Aligning Crankshaft Pulley Bolt Holes
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 68: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 69: 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 70: Identifying Special Tool
Courtesy of FORD MOTOR CO.

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

Fig 71: 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 72: 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 73: Identifying Special Camshaft Tool (303-465)
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 74: 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 75: 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 76: Locating CKP Sensor Alignment Tool And Bolts
  Courtesy of FORD MOTOR CO.
Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

Fig 77: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 78: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 79: 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.
Apply silicone gasket and sealant to the locations shown.

Fig 80: Identifying Location Of Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.

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.

Install the valve cover.
- Tighten the 14 bolts in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 81: Identifying Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install a new cylinder head temperature (CHT) sensor and the spark plugs.
- Tighten the CHT sensor to 12 Nm (9 lb-ft).
- Tighten the spark plugs to 12 Nm (9 lb-ft).
  
  Fig 82: Locating Cylinder Head Temperature Sensor And Spark Plugs
  Courtesy of FORD MOTOR CO.

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

Install the 4 coil-on-plugs, 4 bolts and the crankcase vent tube.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 83: Locating Crankcase Vent Tube And Coil-On-Plugs
  Courtesy of FORD MOTOR CO.
If equipped, install the block heater.
- Tighten to 21 Nm (15 lb-ft).
  
  Fig 84: Locating Block Heater
  Courtesy of FORD MOTOR CO.

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

Install the crankcase vent oil separator and the KS.
- Tighten the 8 oil separator bolts to 10 Nm (89 lb-in).
- Tighten the KS to 20 Nm (15 lb-ft).
  
  Fig 85: Locating Crankcase Vent Oil Separator, KS And Bolts
  Courtesy of FORD MOTOR CO.
Install the coolant bypass hose.

Fig 86: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
Using a new gasket, install the coolant bypass and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 87: Locating Coolant Bypass And Bolts
  Courtesy of FORD MOTOR CO.
Connect the coolant bypass hose.

Fig 88: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
Install the coolant hose.

Fig 89: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Position the engine control wiring harness on the engine and connect the CHT sensor and install the rubber boot.

Fig 90: Locating CHT Sensor And Rubber Boot
Courtesy of FORD MOTOR CO.
Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.

Fig 91: Locating Camshaft Position Sensor Electrical Connectors
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 92: Locating Fuel Injector O-Ring Seals
  Courtesy of FORD MOTOR CO.
Install the fuel rail with the fuel injectors and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 93: Locating Fuel Rail And Bolts
  Courtesy of FORD MOTOR CO.
Connect the fuel charging wiring harness.
- Connect the fuel rail pressure and temperature sensor electrical connector.
- Connect the 4 fuel injector electrical connectors.
- Attach the wiring harness retainers.
  
  Fig 94: Locating Electrical Connectors And Wiring Harness Retainers
  Courtesy of FORD MOTOR CO.
Connect the wiring harness retainers to the valve cover studs.

Fig 95: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Install the radio interference capacitor bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 96: Locating Radio Interference Capacitor Bracket Bolt
  Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 97: Locating EGR Tube
  Courtesy of FORD MOTOR CO.
Inspect and install new intake manifold gaskets if necessary.
Position the intake manifold and connect the positive crankcase ventilation (PCV) hose.

Fig 98: Locating Positive Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.

2.3L engines

NOTE: Be sure to install the bolts in the previously marked locations.

Install the intake manifold and the 7 mounting bolts.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 99: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring with clean engine oil.

Fig 100: Locating Oil Level Indicator Tube Assembly Bolts

Courtesy of FORD MOTOR CO.

Install the oil level indicator tube assembly and 2 bolts.
Connect the swirl valve electrical connectors and pin-type retainers.

Fig 101: Locating Swirl Valve Electrical Connectors And Pin-Type Retainers
Courtesy of FORD MOTOR CO.

2.0L engines

NOTE: Be sure to install the bolts in the previously marked locations.

Install the intake manifold and the 7 mounting bolts.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 102: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring with clean engine oil.

Install the oil level indicator tube assembly and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 103: Locating Oil Level Indicator Tube Assembly And Bolt
  Courtesy of FORD MOTOR CO.
Connect the swirl control valve electrical connector.

Fig 104: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
If equipped, connect the secondary air injection (AIR) vacuum supply hose.

Fig 105: Locating Secondary Air Injection (AIR) Vacuum Supply Hose
Courtesy of FORD MOTOR CO.

All engines

Connect the manifold absolute pressure (MAP) electrical connector.

Fig 106: Locating Manifold Absolute Pressure Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the intake manifold runner control (IMRC) actuator electrical connector.

Fig 107: Locating Intake Manifold Runner Control Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the wiring harness pin-type retainer.

Fig 108: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Connect the fuel rail pressure and temperature sensor vacuum hose.

Fig 109: Locating Fuel Rail Pressure And Temperature Sensor Vacuum Hose
Courtesy of FORD MOTOR CO.
Connect the idle air control (IAC) valve electrical connector and wiring harness pin-type retainer.

Fig 110: Locating Idle Air Control Valve Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Connect the throttle position (TP) sensor electrical connector and wiring harness pin-type retainer.

Fig 111: Locating Throttle Position Sensor Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Install the lower intake bolt.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 112: Locating Lower Intake Bolt
  Courtesy of FORD MOTOR CO.
Connect the KS electrical connector and pin-type retainer.

Fig 113: Locating KS Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

NOTE: Clean the gasket mating surfaces with metal surface cleaner.

Install the oil filter adapter with a new gasket.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 114: Locating Oil Filter Adapter Bolts
  Courtesy of FORD MOTOR CO.
Install a new oil filter.
- Tighten the oil filter 3/4 turn after the oil filter gasket makes contact with the oil filter adapter.
  
  Fig 115: Locating Oil Filter
  Courtesy of FORD MOTOR CO.
Connect the oil pressure sensor electrical connector.

Fig 116: Locating Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

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

Install the thermostat housing and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 117: Locating Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Connect the heater hose to the thermostat housing.

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

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

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

Position the coolant pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 119: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 120: Locating Coolant Pump Pulley Bolts
  Courtesy of FORD MOTOR CO.
If equipped, install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 121: Locating Accessory Drive Belt Idler Pulley And Bolt
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 122: Locating Accessory Drive Belt Idler Pulley And Bolt
  Courtesy of FORD MOTOR CO.
Install the accessory drivebelt tensioner and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 123: Locating Accessory Drivebelt Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Install the generator, bolt and 2 stud bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 124: Locating Generator And Bolts
  Courtesy of FORD MOTOR CO.
Install the wiring harness retainer and nut.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 125: Locating Wiring Harness Retainer And Nut
  Courtesy of FORD MOTOR CO.
Connect the generator electrical connections, harness retainer and install the nut.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 126: Locating Generator Electrical Connections, Harness Retainer And Nut
  Courtesy of FORD MOTOR CO.
Install the generator heat shield and 2 nuts.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 127: Locating Generator Heat Shield And Nuts
  Courtesy of FORD MOTOR CO.
Connect the CKP sensor and the wiring harness pin-type retainers.

Fig 128: Locating CKP Sensor And Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
Install the flexplate and the 6 bolts. Tighten the 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 129: Identifying Flexplate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

Engines equipped with a manual transmission

Lubricate the transaxle input shaft pilot bearing with front axle grease.

Fig 130: Locating Transaxle Input Shaft Pilot Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, position the clutch disc on the flywheel.

Fig 131: 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.

Fig 132: Locating Clutch Pressure Plate Bolts

Courtesy of FORD MOTOR CO.

Position the clutch pressure plate and install the 7 bolts. Tighten the bolts in a star pattern sequence to 27 Nm (20 lb-ft).