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Engine Mechanical: Mechanical: Engine: Assembly: Engine

SPECIAL TOOL SPECIFICATION

G06061955Courtesy of FORD MOTOR CO.
 Alignment Pins
307-399
G06095238Courtesy of FORD MOTOR CO.
 Compressor, Piston Ring
303-D032 (D81L-6002-C)
G06064974Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C)
G06068143Courtesy of FORD MOTOR CO.
 Eye, Engine Lift
303-1245
G06061923Courtesy of FORD MOTOR CO.
 Handle
205-153 (T80T-4000-W)
G06062108Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G06061935Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Vibration Damper
303-102 (T74P-6316-B)
G06061934Courtesy of FORD MOTOR CO.
 Installer, Front Cover Oil Seal
303-335
G06062772Courtesy of FORD MOTOR CO.
 Installer, Front Crankshaft Seal
303-1251
G06062553Courtesy of FORD MOTOR CO.
 Installer, Rear Main Seal
303-1250
G06073733Courtesy of FORD MOTOR CO.
 Installer, VCT Spark Plug Tube Seal
303-1247/2
G06062110Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G06062185Courtesy of FORD MOTOR CO.
 Strap Wrench
303-D055 (D85L-6000-A) or equivalent
G06063035Courtesy of FORD MOTOR CO.
 Tool, Camshaft Holding
303-1248
Material

Item Specification
Motorcraft High Performance Engine RTV Silicone
TA-357		 WSE-M4G323-A6
Motorcraft Metal Surface Prep
ZC-31-A		 -
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)		 WSS-M97B51-A1
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
Silicone Gasket Remover
ZC-30		 -
Threadlock and Sealer TA-25 WSK-M2G351-A5
Thread Sealant with PTFE
TA-24		 WSK-M2G350-A2
Fig 1: Identifying Engine Upper Components
GF0043861Courtesy of FORD MOTOR CO.
Item Part Number Description
1 12C508 Engine control harness
2 9S455 Upper intake manifold
3 9F797 Fuel rail
4 9J444 Upper intake manifold bracket
5 9K461 Lower intake manifold
6 8A856 Thermostat housing
7 9N271 Coolant tube
8 9N271 Knock sensor (KS)
9 6010 Cylinder block
Fig 2: Identifying Engine Front Components
GF0029294Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6A0003 Engine mount bracket
2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley washer
4 6316 Crankshaft pulley
5 6700 Crankshaft front seal
6 6C086 Engine front cover
7 6268 Timing chain
8 6306 Crankshaft timing sprocket
9 6K254 Primary timing chain tensioner
10 6K255 Primary timing chain tensioner arm
11 6B274 LH lower primary timing chain guide
12 6M256 RH primary timing chain guide
13 6K297 LH upper primary timing chain guide
14 8501 Coolant pump
15 6010 Cylinder block
Fig 3: Identifying Cylinder Block Components - Lower Side 1
G06252043Courtesy of FORD MOTOR CO.
DESCRIPTION CHART

Item Part Number Description
1 6675 Oil pan
2 6622 Oil pump screen and pickup tube
3 6625 Oil pump screen and pickup tube O-ring seal
4 6621 Oil pump
5 6010 Cylinder block
6 6D327 Crankshaft rear seal retainer
7 12A227 Crankshaft sensor ring
8 6375 Flexplate
9 6881 Oil filter adapter
10 9278 Engine Oil Pressure (EOP) switch
Fig 4: Identifying Cylinder Block Components - Lower Side 2
G06252044Courtesy of FORD MOTOR CO.
DESCRIPTION CHART

Item Part Number Description
1 6150 Piston compression upper ring (6 required)
2 6152 Piston compression lower ring (6 required)
3 6159 Piston oil control upper segment ring (6 required)
4 6161 Piston oil control spacer (6 required)
5 6159 Piston oil control lower segment ring (6 required)
6 6140 Piston pin retainer (12 required)
7 6135 Piston pin (6 required)
8 6110 Piston (6 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
11 6211 Connecting rod lower bearing (6 required)
12 6210 Connecting rod cap (6 required)
13 6010 Cylinder block
14 6A341 Crankshaft upper thrust washer (2 required)
15 6333 Cylinder block crankshaft main bearing (4 required)
16 6303 Crankshaft
17 6K302 Crankshaft lower thrust washer
18 6333 Lower crankshaft main bearings (4 required)
19 6325 Lower crankshaft main bearing caps (4 required)
20 6C364 Main bearing cap support brace
Fig 5: Exploded View Of LH Cylinder Head
GF0029296Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6083 LH cylinder head gasket
2 6C261 LH variable camshaft timing (VCT) housing
3 W12244 LH exhaust manifold stud (6 required)
4 6500 Valve tappet (32 required)
5 6050 LH cylinder head
6 6279 LH camshaft bolt (2 required)
7 W710738 LH exhaust camshaft sprocket washer
8 6C524 LH VCT assembly
9 6256 LH exhaust camshaft sprocket
10 6C256 LH secondary timing chain
11 6A258 LH camshaft cap (8 required)
12 6A505 LH valve cover
13 6A267 LH intake camshaft
14 6A269 LH exhaust camshaft
15 6C271 LH secondary timing chain tensioner
Fig 6: Exploded View Of RH Cylinder Head
GF0041335Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W712244 RH exhaust manifold stud (6 required)
2 6051 RH cylinder head gasket
3 6G004 Cylinder head temperature (CHT) sensor
4 14B485 CHT sensor jumper harness
5 6B288 Camshaft position (CMP) sensor (2 required)
6 6049 RH cylinder head
7 17A084 Engine lift eye
8 6C260 RH variable camshaft timing (VCT) housing
9 6279 RH camshaft bolt (2 required)
10 W710738 RH exhaust camshaft sprocket washer
11 6256 RH exhaust camshaft sprocket
12 6C524 RH VCT assembly
13 6C256 RH secondary timing chain
14 6A266 RH intake camshaft
15 6A268 RH exhaust camshaft
16 12405 Spark plug (6 required)
17 6A258 RH camshaft cap (8 required)
18 6582 RH valve cover
19 12A375 Coil-on-plug (6 required)
20 6C270 RH secondary timing chain tensioner
NOTE: 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.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

All vehicles 

  1. 1.

    NOTE: This step is for selecting the correct main bearings.

    NOTE: The #1 main bearing is at the front of the engine block.

    Select the crankshaft main bearings for each crankshaft journal.

    • Record the code that is on the cylinder block face.
    • Record the code that is on the crankshaft flange.
    • The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
GFD119421Courtesy of FORD MOTOR COMPANY

  1. 2.

    NOTE: This chart is continued in the next step.

    NOTE: This chart is for selecting main bearings 1 and 4 only.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 4.

    • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1 crankshaft main bearing.
    • As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
    • Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
GFD119422Courtesy of FORD MOTOR COMPANY

  1. 3.

    NOTE: This chart is for selecting main bearings 1 and 4 only.
GFD119423Courtesy of FORD MOTOR COMPANY

  1. 4.

    NOTE: This chart is continued in the next step.

    NOTE: This chart is for selecting main bearings 2 and 3 only.

    Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2 and 3.

    • Read the second letter of the engine block main bearing code and the second letter of the crankshaft main bearing code.
    • Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2 crankshaft main bearing.
    • As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing grade for this main bearing is "2".
    • Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
GFD119424Courtesy of FORD MOTOR COMPANY

  1. 5.

    NOTE: This chart is for selecting main bearings 2 and 3 only.
GFD119425Courtesy of FORD MOTOR COMPANY

  1. 6.

    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 rod caps and bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.

  1. 7.

    Measure the connecting rod large end bore in 2 directions.
    • Remove the bolts and the rod cap.
      • Discard the connecting rod cap bolts.
GFD119426Courtesy of FORD MOTOR COMPANY

  1. 8.

    Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
GFD119427Courtesy of FORD MOTOR COMPANY

  1. 9.

    Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
GFD119428Courtesy of FORD MOTOR COMPANY

  1. 10.

    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.

    Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main bearings in the cylinder block.

GFD119404Courtesy of FORD MOTOR COMPANY

  1. 11.

    NOTE: Do not install the upper thrust bearings until the crankshaft is installed.

    NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.

    Install the crankshaft onto the upper main bearings.

GFD119402Courtesy of FORD MOTOR COMPANY

  1. 12.

    NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear bulkhead.

GFD119429Courtesy of FORD MOTOR COMPANY

  1. 13.

    NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear bulkhead.

GFD119430Courtesy of FORD MOTOR COMPANY

  1. 14.

    Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating in caps.
GFD119405Courtesy of FORD MOTOR COMPANY

  1. 15.

    Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
GFD119431Courtesy of FORD MOTOR COMPANY

  1. 16.

    NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.

    NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

    Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned with the cutout in the main bearing cap.

GFD119432Courtesy of FORD MOTOR COMPANY

  1. 17.

    Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
GFD119433Courtesy of FORD MOTOR COMPANY

  1. 18.

    Loosen the No. 4 main bearing cap bolts.

  1. 19.

    NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap rearward to seat the crankshaft thrust washers.

    Tighten the main bearing bolts in the sequence shown in 2 stages.

    • Stage 1: Tighten fasteners 1 through 8 to 60 Nm (44 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
Fig 7: Main Bearing Vertical Bolts Tightening Sequence
GFD119434Courtesy of FORD MOTOR COMPANY

  1. 20.

    Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten fasteners 1 through 8 to 45 Nm (33 lb-ft).
    • Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
Fig 8: Main Bearing Cap Side Bolts Tightening Sequence
GFD119435Courtesy of FORD MOTOR COMPANY

  1. 21.

    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.
    • Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
GFD119436Courtesy of FORD MOTOR COMPANY

  1. 22.

    NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Prepare the connecting rod and cap.

    • Insert the new bolts in the rod cap.
    • Insert the upper and lower rod bearings into the rod and cap.
GFD119437Courtesy of FORD MOTOR COMPANY

  1. 23.

    Before installing the pistons into the cylinder block, verify proper ring gap location.

    1. 1.

      Center line of the piston parallel to the wrist pin bore

    1. 2.

      Upper compression ring gap location

    1. 3.

      Upper oil control segment ring gap location

    1. 4.

      Lower oil control segment ring gap location

    1. 5.

      Expander ring and lower compression ring gap location
GFD119412Courtesy of FORD MOTOR COMPANY

  1. 24.

    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: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod, rod cap and piston is shown.

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

    NOTE: Make sure the piston rings are positioned to specifications for installation. For additional information, refer to in this section.

    NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.

    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

    Using the Piston Ring Compressor, install the piston and connecting rod assemblies.

GFD119438Courtesy of FORD MOTOR COMPANY

  1. 25.

    Seat the connecting rod on the crankshaft journal.

  1. 26.

    NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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

    Install the connecting rod cap and bolts.

    • Tighten the bolts in 3 stages.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90 degrees.
Fig 9: Connecting Rod Cap Bolts Tightening Sequence
GFD119439Courtesy of FORD MOTOR COMPANY

  1. 27.

    Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.

  1. 28.

    Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2 steps.
    • Stage 1: Tighten fasteners to 20 Nm (177 lb-in).
    • Stage 2: Tighten fasteners an additional 180 degrees.
Fig 10: Main Bearing Cap Support Brace Bolts Tightening Sequence
GFD119440Courtesy of FORD MOTOR COMPANY

  1. 29.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 4 minutes of sealant application.

    Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the crankshaft rear seal retainer.

GFD119441Courtesy of FORD MOTOR COMPANY

  1. 30.

    Install the crankshaft rear seal retainer and the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 11: Crankshaft Rear Seal Retainer Bolts Tightening Sequence
GFD119442Courtesy of FORD MOTOR COMPANY

  1. 31.

    Install the oil pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119232Courtesy of FORD MOTOR COMPANY

  1. 32.

    Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119394Courtesy of FORD MOTOR COMPANY

  1. 33.

    NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.

    Install the A/C compressor and the 2 bolts.

    • Tighten to 25 Nm (18 lb-ft).
GFD119443Courtesy of FORD MOTOR COMPANY

  1. 34.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block and A/C compressor within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.

    Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

    • Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
GFD119444Courtesy of FORD MOTOR COMPANY

  1. 35.

    NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.

    Install the oil pan and bolts 10, 11, 13 and 14.

    • Tighten the bolts in the sequence shown to 3 Nm (27 lb-in).
    • Loosen the bolts 180 degrees.
Fig 12: Oil Pan Bolts Tightening Sequence
GFD119445Courtesy of FORD MOTOR COMPANY

  1. 36.

    Align the oil pan to the cylinder block and the A/C compressor.
    • Position the oil pan so the mounting boss is against the A/C compressor and using a straightedge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown.
GFD119446Courtesy of FORD MOTOR COMPANY

  1. 37.

    Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
Fig 13: Oil Pan Bolts Tightening Sequence
GFD119445Courtesy of FORD MOTOR COMPANY

  1. 38.

    Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
    • Tighten the large bolts (1-14) to 24 Nm (18 lb-ft).
    • Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
Fig 14: Oil Pan Bolts Tightening Sequence
GFD119447Courtesy of FORD MOTOR COMPANY

  1. 39.

    Install the A/C compressor mounting stud and nut.
    • Tighten the stud to 9 Nm (80 lb-in) and the nut to 25 Nm (18 lb-ft).
GFD119448Courtesy of FORD MOTOR COMPANY

  1. 40.

    Install the coolant pump and the 8 bolts. Tighten in the sequence shown in 2 stages:
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
Fig 15: Coolant Pump Bolts Tightening Sequence
GFD119449Courtesy of FORD MOTOR COMPANY

  1. 41.

    Install the Knock Sensor(KS) and the 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
GFD119390Courtesy of FORD MOTOR COMPANY

  1. 42.

    NOTE: Apply clean engine coolant to the O-ring seals prior to installation.

    Using new O-ring seals, install the coolant inlet tube.

GFD119389Courtesy of FORD MOTOR COMPANY

  1. 43.

    Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 90 degrees.
Fig 16: RH Cylinder Head Bolts Tightening Sequence
GFD119450Courtesy of FORD MOTOR COMPANY

  1. 44.

    Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119353Courtesy of FORD MOTOR COMPANY

  1. 45.

    Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 90 degrees.
Fig 17: LH Cylinder Head Bolts Tightening Sequence
GFD119451Courtesy of FORD MOTOR COMPANY

  1. 46.

    Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119369Courtesy of FORD MOTOR COMPANY

  1. 47.

    NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Position the crankshaft dowel pin in the 9 o'clock position.

GFD119452Courtesy of FORD MOTOR COMPANY

  1. 48.

    NOTE: The valve tappets must be installed in their original positions.

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

    NOTE: LH shown, RH similar.

    Install the valve tappets.

GFD119326Courtesy of FORD MOTOR COMPANY

  1. 49.

    NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.

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

    Position the camshafts onto the RH cylinder head in the neutral position as shown.

GFD119453Courtesy of FORD MOTOR COMPANY

  1. 50.

    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.

    Install the 8 camshaft caps and the 16 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 18: Camshaft Caps Bolts Tightening Sequence
GFD119454Courtesy of FORD MOTOR COMPANY

  1. 51.

    NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.

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

    Position the camshafts onto the LH cylinder head in the neutral position as shown.

GFD119455Courtesy of FORD MOTOR COMPANY

  1. 52.

    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.

    Install the 8 camshaft caps and the 16 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 19: Camshaft Caps Bolts Tightening Sequence
GFD119456Courtesy of FORD MOTOR COMPANY

  1. 53.

    NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to Valve Clearance Check  in this section.

GFD119457Courtesy of FORD MOTOR COMPANY

  1. 54.

    Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119160Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 55.

    Install the RH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119345Courtesy of FORD MOTOR COMPANY

  1. 56.

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the RH camshafts to the top dead center position and install the Camshaft Holding Tool on the flats of the camshafts.

GFD119458Courtesy of FORD MOTOR COMPANY

  1. 57.

    Assemble the RH Variable Camshaft Timing(VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
    • Align the colored links with the timing marks.
GFD119162Courtesy of FORD MOTOR COMPANY

  1. 58.

    Position the RH secondary timing assembly onto the camshafts.
GFD119163Courtesy of FORD MOTOR COMPANY

  1. 59.

    Install 2 new bolts and the original washer. Tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.
Fig 20: New Bolts Tightening Sequence
GFD119158Courtesy of FORD MOTOR COMPANY

  1. 60.

    Remove the lockpin from the RH secondary timing chain tensioner.
GFD119164Courtesy of FORD MOTOR COMPANY

  1. 61.

    Install the LH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119368Courtesy of FORD MOTOR COMPANY

  1. 62.

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Rotate the LH camshafts to the Top Dead Center(TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.

GFD119459Courtesy of FORD MOTOR COMPANY

  1. 63.

    Assemble the LH Variable Camshaft Timing(VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
    • Align the colored links with the timing marks.
GFD119165Courtesy of FORD MOTOR COMPANY

  1. 64.

    Position the LH secondary timing assembly onto the camshafts.
GFD119166Courtesy of FORD MOTOR COMPANY

  1. 65.

    Install 2 new bolts and the original washer. Tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 10 Nm (89 lb-in).
    • Stage 4: Tighten 90 degrees.
Fig 21: New Bolts Tightening Sequence
GFD119155Courtesy of FORD MOTOR COMPANY

  1. 66.

    Remove the lockpin from the LH secondary timing chain tensioner.
GFD119167Courtesy of FORD MOTOR COMPANY

  1. 67.

    Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
GFD119460Courtesy of FORD MOTOR COMPANY

  1. 68.

    Install the crankshaft timing chain sprocket.
GFD119152Courtesy of FORD MOTOR COMPANY

  1. 69.

    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
GFD119168Courtesy of FORD MOTOR COMPANY

  1. 70.

    Install the upper LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119153Courtesy of FORD MOTOR COMPANY

  1. 71.

    Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119150Courtesy of FORD MOTOR COMPANY

  1. 72.

    Install the primary timing chain tensioner arm.
GFD119149Courtesy of FORD MOTOR COMPANY

  1. 73.

    Reset the primary timing chain tensioner.
    • Rotate the lever counterclockwise.
    • Using a soft-jawed vise, compress the plunger.
    • Align the hole in the lever with the hole in the tensioner housing.
    • Install a suitable lockpin.
GFD119169Courtesy of FORD MOTOR COMPANY

  1. 74.

    NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.
GFD119170Courtesy of FORD MOTOR COMPANY

  1. 75.

    As a post-check, verify correct alignment of all timing marks.
    • There are 38 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 27 links in between LH intake VCT assembly colored link (2) and the crankshaft sprocket link (3).
GFD119171Courtesy of FORD MOTOR COMPANY

  1. 76.

    Inspect the VCT housing seals for damage and replace as necessary.
GFD119172Courtesy of FORD MOTOR COMPANY

  1. 77.

    NOTE: Make sure the dowels on the Variable Camshaft Timing(VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

    Install the LH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 22: LH VCT Housing Bolts Tightening Sequence
GFD119173Courtesy of FORD MOTOR COMPANY

  1. 78.

    NOTE: Make sure the dowels on the Variable Camshaft Timing(VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

    Install the RH VCT housing and the 3 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 23: RH VCT Housing Bolts Tightening Sequence
GFD119137Courtesy of FORD MOTOR COMPANY

  1. 79.

    Install the Alignment Pins.
GFD119133Courtesy of FORD MOTOR COMPANY

  1. 80.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

    Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.

    • Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
GFD119134Courtesy of FORD MOTOR COMPANY

  1. 81.

    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and bolts 17, 18, 19 and 20.

    • Tighten in sequence to 3 Nm (27 lb-in).
Fig 24: Engine Front Cover Bolts Tightening Sequence
GFD119135Courtesy of FORD MOTOR COMPANY

  1. 82.

    Remove the Alignment Pins.
GFD119136Courtesy of FORD MOTOR COMPANY

  1. 83.

    NOTE: Do not tighten the bolts at this time.

    Install the engine mount bracket and the 3 bolts.

GFD119316Courtesy of FORD MOTOR COMPANY

  1. 84.

    NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:

    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
Fig 25: Engine Front Cover Bolts Tightening Sequence
GFD119137Courtesy of FORD MOTOR COMPANY

  1. 85.

    NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

    Install the engine mount studs in the following sequence.

    1. 1.

      Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.

    1. 2.

      Clean all the thread sealer from the engine mount studs (old and new studs).

    1. 3.

      Apply new Threadlock and Sealer to the engine mount stud threads.

    1. 4.

      Install the 2 engine mount studs.
      • Tighten to 20 Nm (177 lb-in).
Fig 26: Engine Mount Studs Tightening Sequence
GFD119128Courtesy of FORD MOTOR COMPANY

  1. 86.

    Install the engine mount bracket and the 2 bolts.
    • Tighten to 30 Nm (22 lb-ft).
GFD119127Courtesy of FORD MOTOR COMPANY

  1. 87.

    NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

GFD119096Courtesy of FORD MOTOR COMPANY

  1. 88.

    NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.

GFD119091Courtesy of FORD MOTOR COMPANY

  1. 89.

    Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
Fig 27: Crankshaft Pulley Washer Bolts Tightening Sequence
GFD119092Courtesy of FORD MOTOR COMPANY

  1. 90.

    NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

    NOTE: Spark plug tube seal installation shown, VCT seal installation similar.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.

GFD119075Courtesy of FORD MOTOR COMPANY

  1. 91.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

    Apply a 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

GFD119081Courtesy of FORD MOTOR COMPANY

  1. 92.

    Using a new gasket, install the RH valve cover and tighten the bolt and the 10 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 28: RH Valve Cover Bolts Tightening Sequence
GFD119083Courtesy of FORD MOTOR COMPANY

  1. 93.

    NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

    Apply a 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

GFD119076Courtesy of FORD MOTOR COMPANY

  1. 94.

    Using a new gasket, install the LH valve cover and tighten the 11 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 29: LH Valve Cover Bolts Tightening Sequence
GFD119078Courtesy of FORD MOTOR COMPANY

  1. 95.

    NOTE: LH shown, RH similar.

    Install the 6 coil-on-plug assemblies and the 6 bolts.

    • Tighten to 7 Nm (62 lb-in).
GFD119311Courtesy of FORD MOTOR COMPANY
    NOTE: Engine without oil cooler shown, engine with oil cooler similar.

  1. 96.
    Using a new gasket and O-ring seal, install the oil filter adapter and the 2 bolts.
    • Tighten the large bolt to 57 Nm (42 lb-ft).
    • Tighten the small bolt to 10 Nm (89 lb-in).
G00565898Courtesy of FORD MOTOR COMPANY
    NOTE: A new oil cooler must be installed or severe damage to the engine may occur.

  1. 97.
    If equipped, install a new oil cooler, new gaskets and the 6 bolts.
    • Tighten to 10 Nm (89 lb-in).
G00565899Courtesy of FORD MOTOR COMPANY

  1. 98.

    NOTE: Apply thread sealant with PTFE to the Engine Oil Pressure(EOP) switch threads.

    Install the EOP switch.

    • Tighten to 18 Nm (159 lb-in).
GFD119383Courtesy of FORD MOTOR COMPANY

  1. 99.

    Install the Crankshaft Position(CKP) sensor and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119382Courtesy of FORD MOTOR COMPANY

  1. 100.

    Install LH Camshaft Position(CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119367Courtesy of FORD MOTOR COMPANY

  1. 101.

    Install and connect the Cylinder Head Temperature(CHT) sensor jumper harness.
GFD119352Courtesy of FORD MOTOR COMPANY

  1. 102.

    NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Using new gaskets, install the lower intake manifold and the 10 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 30: Lower Intake Manifold Bolts Tightening Sequence
GFD119068Courtesy of FORD MOTOR COMPANY

  1. 103.

    Using a new gasket, install the thermostat housing and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119350Courtesy of FORD MOTOR COMPANY

  1. 104.

    NOTE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.

    NOTE: The upper and lower O-ring seals are not interchangeable.

    Install new fuel injector O-ring seals.

    • Remove the retaining clips and separate the fuel injectors from the fuel rail.
    • Remove and discard the O-ring seals.
    • Install new O-ring seals and lubricate with clean engine oil.
    • Install the fuel injectors and the retaining clips onto the fuel rail.
GFD119461Courtesy of FORD MOTOR COMPANY

  1. 105.

    Install the fuel rail and injectors as an assembly and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119349Courtesy of FORD MOTOR COMPANY

All-Wheel Drive(AWD) vehicles 

  1. 106.

    Install the catalytic converter bracket and the 2 bolts.
    • Tighten to 48 Nm (35 lb-ft).
GFD119294Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 107.

    Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119348Courtesy of FORD MOTOR COMPANY

  1. 108.

    Install the engine lifting eye and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
GFD119346Courtesy of FORD MOTOR COMPANY

  1. 109.

    Install the cover and the pin-type retainer.
GFD119381Courtesy of FORD MOTOR COMPANY

  1. 110.

    Install the LH cylinder block drain plug.
    • Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
GFD119341Courtesy of FORD MOTOR COMPANY

  1. 111.

    Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten to 40 Nm (30 lb-ft).
GFD119342Courtesy of FORD MOTOR COMPANY

  1. 112.

    Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
GFD119181Courtesy of FORD MOTOR COMPANY

  1. 113.

    NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
Fig 31: Exhaust Manifold Nuts Tightening Sequence
GFD119182Courtesy of FORD MOTOR COMPANY

Front Wheel Drive(FWD) vehicles 

  1. 114.

    Install the RH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119343Courtesy of FORD MOTOR COMPANY

  1. 115.

    Using a new gasket, install the RH catalytic converter and the 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
GFD119293Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 116.

    Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (106 lb-in).
GFD119178Courtesy of FORD MOTOR COMPANY

  1. 117.

    NOTE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

    Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
Fig 32: Exhaust Manifold Nuts Tightening Sequence
GFD119462Courtesy of FORD MOTOR COMPANY

  1. 118.

    Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
GFD119365Courtesy of FORD MOTOR COMPANY

  1. 119.

    Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
    • Tighten to 40 Nm (30 lb-ft).
GFD119340Courtesy of FORD MOTOR COMPANY

  1. 120.

    Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
GFD119315Courtesy of FORD MOTOR COMPANY

  1. 121.

    Install the power steering pump and the 3 bolts.
    • Tighten to 24 Nm (18 lb-ft).
GFD119291Courtesy of FORD MOTOR COMPANY

  1. 122.

    Install the generator, the bolt and the nut.
    • Tighten to 47 Nm (35 lb-ft).
GFD119364Courtesy of FORD MOTOR COMPANY

  1. 123.

    Position the wiring harness onto the engine.

  1. 124.

    Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
GFD119362Courtesy of FORD MOTOR COMPANY

  1. 125.

    Attach the wiring harness retainer to the generator.
GFD119361Courtesy of FORD MOTOR COMPANY

  1. 126.

    Connect the generator electrical connector.
GFD119360Courtesy of FORD MOTOR COMPANY

  1. 127.

    Connect the generator B+ cable and install the nut.
    • Tighten to 17 Nm (150 lb-in).
GFD119359Courtesy of FORD MOTOR COMPANY

  1. 128.

    Connect the A/C compressor electrical connector.
GFD119358Courtesy of FORD MOTOR COMPANY

  1. 129.

    Connect the CKP sensor electrical connector.
GFD119379Courtesy of FORD MOTOR COMPANY

  1. 130.

    Install the wiring harness grommet.
GFD119378Courtesy of FORD MOTOR COMPANY

  1. 131.

    Install the wiring harness retainer stud bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119377Courtesy of FORD MOTOR COMPANY

  1. 132.

    Install the heat shield, the nut and the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119376Courtesy of FORD MOTOR COMPANY

  1. 133.

    Install the wiring harness retainer bolt on the rear of the LH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
GFD119357Courtesy of FORD MOTOR COMPANY

  1. 134.

    Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

  1. 135.

    Connect the LH camshaft VCT solenoid electrical connector.
GFD119309Courtesy of FORD MOTOR COMPANY

  1. 136.

    Connect the 3 LH coil-on-plug electrical connectors.
GFD119310Courtesy of FORD MOTOR COMPANY

  1. 137.

    Connect the LH Heated Oxygen Sensor(HO2S) electrical connector.
GFD119356Courtesy of FORD MOTOR COMPANY

  1. 138.

    Connect the LH Catalyst Monitor Sensor(CMS) electrical connector.
GFD119338Courtesy of FORD MOTOR COMPANY

  1. 139.

    Connect the LH CMP sensor electrical connector.
GFD119355Courtesy of FORD MOTOR COMPANY

  1. 140.

    Connect the CHT sensor electrical connector.
GFD119337Courtesy of FORD MOTOR COMPANY

  1. 141.

    Connect the 6 fuel injector electrical connectors (3 shown).
GFD119336Courtesy of FORD MOTOR COMPANY

  1. 142.

    Install the ground cable and the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD119335Courtesy of FORD MOTOR COMPANY

  1. 143.

    Connect the KS electrical connector.
GFD119375Courtesy of FORD MOTOR COMPANY

  1. 144.

    Connect the RH CMP sensor electrical connector.
GFD119334Courtesy of FORD MOTOR COMPANY

  1. 145.

    Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

  1. 146.

    Connect the 3 RH coil-on-plug electrical connectors.
GFD119374Courtesy of FORD MOTOR COMPANY

  1. 147.

    Connect the RH VCT solenoid electrical connector.
GFD119307Courtesy of FORD MOTOR COMPANY

FWD vehicles 

  1. 148.

    Connect the RH CMS electrical connector.
GFD119289Courtesy of FORD MOTOR COMPANY

All vehicles 

  1. 149.

    Connect the Power Steering Pressure(PSP) switch electrical connector.
GFD119290Courtesy of FORD MOTOR COMPANY

  1. 150.

    NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Using a new gasket, install the upper intake manifold and the 6 bolts.

    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 33: Upper Intake Manifold Bolts Tightening Sequence
GFD119066Courtesy of FORD MOTOR COMPANY

  1. 151.

    Install the upper intake manifold support bracket and the 2 bolts (1 shown).
    • Tighten to 10 Nm (89 lb-in).
GFD119463Courtesy of FORD MOTOR COMPANY

  1. 152.

    Connect the RH HO2S electrical connector.
GFD119333Courtesy of FORD MOTOR COMPANY

  1. 153.

    Attach the wiring harness retainers to the upper intake manifold.
GFD119304Courtesy of FORD MOTOR COMPANY

  1. 154.

    Connect the Throttle Body(TB) electrical connector.
GFD119303Courtesy of FORD MOTOR COMPANY

  1. 155.

    Connect the PCV hose to the PCV valve.
GFD119373Courtesy of FORD MOTOR COMPANY

  1. 156.

    If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.

  1. 157.

    If equipped, connect the block heater electrical connector and install the heat shield.
GFD119332Courtesy of FORD MOTOR COMPANY

  1. 158.

    Install the Engine Lift Eye on the LH cylinder head.
GFD119282Courtesy of FORD MOTOR COMPANY

  1. 159.

    Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
GFD119464Courtesy of FORD MOTOR COMPANY

  1. 160.

    NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

    Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.

GFD119102Courtesy of FORD MOTOR COMPANY

  1. 161.

    Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
GFD119103Courtesy of FORD MOTOR COMPANY

  1. 162.

    Install the crankshaft sensor ring.
GFD119372Courtesy of FORD MOTOR COMPANY

  1. 163.

    Install the flexplate and the 8 bolts.
    • Tighten to 80 Nm (59 lb-ft).
GFD119371Courtesy of FORD MOTOR COMPANY
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