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Engine Mechanical: Mechanical: Engine: Assembly: Engine

Special Tools

Illustration Tool Name Tool Number
GF0000970
 Alignment Pins 307-399
GF0029191
 Camshaft Alignment Tool 303-1248
GF0029125
 Engine Lifting Bracket 303-1245
GF0000811
 Handle 205-153 (T80T-4000-W)
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0029105
 Installer, Crankshaft Front Seal 303-1251
GF0029109
 Installer, Crankshaft Rear Seal 303-1250
GF0000290
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GF0002553
 Installer, Front Cover Oil Seal 303-335
GF0029085
 Installer, Seal 303-1247/2
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0000246
 Strap Wrench 303-D055 (D85L-6000-A)
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		 -
Thread Sealant with PTFE
TA-24		 WSK-M2G350-A2
Fig 1: Engine Upper
GF0031419Courtesy of FORD MOTOR CO.
Item Part Number Description
1 12C508 Engine control harness
2 9S455 Upper intake manifold
3 9J444 Upper intake manifold long support bracket (early build engines)
4 9F797 Fuel rail
5 9J444 Upper intake manifold short support bracket
6 9K461 Lower intake manifold
7 8A856 Thermostat housing
8 9N271 Coolant tube
9 9N271 Knock sensor (KS)
10 6010 Cylinder block
Fig 2: Engine Front
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: Engine Lower
GF0045687Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6675 Oil pan
2 6622 Oil pump screen and pickup tube
3 6621 Oil pump
4 6010 Cylinder block
5 6D327 Crankshaft rear seal retainer
6 12A227 Crankshaft sensor ring
7 6375 Flexplate
8 6881 Oil filter adapter
9 9278 Engine oil pressure (EOP) switch
Fig 4: 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 5: 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 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
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, may cause engine failure.

All vehicles 

  1. NOTE: This procedure is for selecting bearings using a new crankshaft.

    Select the crankshaft main bearings for each crankshaft journal.

    • Read the code on the crankshaft flange.
    • Read the code on the cylinder block face.
      • The first letter after the first asterisk makes up the code for main No. 1 and the next letter for main No. 2. The first letter after the second asterisk makes up the code for main No. 3 and the last letter for main No. 4.
    Fig 6: Locating Crankshaft Flange
    G06252045Courtesy of FORD MOTOR CO.
  2. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
    • If the block code is *BM*QS* and the crankshaft code is *OL*PO*, Main No. 1 should be built with grade 1 bearings, as determined by the intersection of the B block column and the O crankshaft row on the chart. Mains No. 2, No. 3 and No. 4 should all be grade 2.
    Fig 7: Block And Crankshaft Codes Chart
    G06252046Courtesy of FORD MOTOR CO.
  3. 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.
  4. Measure the connecting rod large end bore in 2 directions.
    • Remove the bolts and the rod cap.
      • Discard the connecting rod cap bolts.
    Fig 8: Measuring Connecting Rod Large End Bore In 2 Directions
    G06064086Courtesy of FORD MOTOR CO.
  5. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
    Fig 9: Measuring Crankshaft Connecting Rod Bearing Journal Diameters In Directions
    G06095259Courtesy of FORD MOTOR CO.
  6. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    Fig 10: Crankshaft Connecting Rod Journal Chart
    G06252049Courtesy of FORD MOTOR CO.
  7. 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.

    Fig 11: Locating Crankshaft Main Bearings
    G06252011Courtesy of FORD MOTOR CO.
  8. 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.

    Fig 12: Locating Crankshaft Thrust Bearings
    G06252009Courtesy of FORD MOTOR CO.
  9. 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.

    Fig 13: Installing Rear Crankshaft Upper Thrust Washer At Back Of No 4 Rear Bulkhead
    G06126704Courtesy of FORD MOTOR CO.
  10. 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.

    Fig 14: Installing Front Crankshaft Upper Thrust Washer At Front Of No 4 Rear Bulkhead
    G06138226Courtesy of FORD MOTOR CO.
  11. 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.
    Fig 15: Locating Main Bearing Caps
    G06252012Courtesy of FORD MOTOR CO.
  12. 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.
    Fig 16: Locating Main Bearing Caps And Bolts
    G06252055Courtesy of FORD MOTOR CO.
  13. 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.

    Fig 17: Locating Lower Crankshaft Thrust Washer To Back Side Of No 4 Rear Main Bearing Cap
    G06252056Courtesy of FORD MOTOR CO.
  14. 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.
    Fig 18: Locating Main Bearing Cap And Bolts
    G06252057Courtesy of FORD MOTOR CO.
  15. Loosen the No. 4 main bearing cap bolts.
  16. 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 illustration 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 19: Identifying Main Bearing Bolts In Tightening Sequence
    G06252058Courtesy of FORD MOTOR CO.
  17. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in illustration 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 20: Identifying Main Bearing Cap Side Bolts In Tightening Sequence
    G06252059Courtesy of FORD MOTOR CO.
  18. 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.
    Fig 21: Measuring Crankshaft End Play
    G06095267Courtesy of FORD MOTOR CO.
  19. 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.
    Fig 22: Locating Bolts In Rod Cap
    G06252061Courtesy of FORD MOTOR CO.
  20. Before installing the pistons into the cylinder block, verify proper ring gap location.
    1. Center line of the piston parallel to the wrist pin bore
    2. Upper compression ring gap location
    3. Upper oil control segment ring gap location
    4. Lower oil control segment ring gap location
    5. Expander ring and lower compression ring gap location
    Fig 23: Identifying Piston Rings Angle
    G06062545Courtesy of FORD MOTOR CO.
  21. 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 in illustration.
    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 Disassembly and Assembly of Subassemblies - DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES .
    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.

    Fig 24: Identifying Piston Ring Compressor
    G06252063Courtesy of FORD MOTOR CO.
  22. Seat the connecting rod on the crankshaft journal.
  23. 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 25: Locating Connecting Rod Cap And Bolts
    G06252064Courtesy of FORD MOTOR CO.
  24. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are installed.
  25. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in illustration in 2 steps.
    • Stage 1: Tighten fasteners to 20 Nm (177 lb-in).
    • Stage 2: Tighten fasteners an additional 180 degrees.
    Fig 26: Identifying Main Bearing Cap Support Brace Tightening Sequence
    G06252065Courtesy of FORD MOTOR CO.
    26. CAUTION: 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.
  26. 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.
    27. Fig 27: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Sealing Surface Of Crankshaft Rear Seal Retainer
    GF0029298Courtesy of FORD MOTOR CO.
  27. Install the crankshaft rear seal retainer and the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    28. Fig 28: Installing Crankshaft Rear Seal Retainer Bolts In Sequence
    GF0029299Courtesy of FORD MOTOR CO.
  28. Install the oil pump and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    29. Fig 29: Identifying Oil Pump & Bolts
    GF0029289Courtesy of FORD MOTOR CO.
  29. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    30. Fig 30: Identifying Oil Pump Screen, Pickup Tube & Bolts
    GF0029267Courtesy of FORD MOTOR CO.
    NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil pan.
  30. Install the A/C compressor and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    31. Fig 31: Identifying A/C Compressor Bolts
    GF0031421Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  31. 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.
    32. Fig 32: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Crankshaft Seal Retainer Plate-To-Cylinder Block
    GF0029301Courtesy of FORD MOTOR CO.
    NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.
  32. 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.
    33. Fig 33: Installing Oil Pan Bolts 10, 11, 13 & 14 In Sequence
    GF0029302Courtesy of FORD MOTOR CO.
  33. Align the oil pan to the cylinder block and 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.
    34. Fig 34: Aligning Oil Pan Flush With Rear Of Cylinder Block
    GF0029303Courtesy of FORD MOTOR CO.
  34. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
    35. Fig 35: Installing Oil Pan Bolts 10, 11, 13 & 14 In Sequence
    GF0029302Courtesy of FORD MOTOR CO.
  35. Install the remaining oil pan bolts. Tighten all the oil pan bolts in the sequence shown.
    • Tighten the large bolts (1-14) to 20 Nm (15 lb-ft).
    • Tighten the small bolts (15 and 16) to 10 Nm (89 lb-in).
    36. Fig 36: Installing Remaining Oil Pan Bolts In Sequence
    GF0029304Courtesy of FORD MOTOR CO.
  36. 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).
    37. Fig 37: Locating A/C Compressor Nut & Stud
    GF0031417Courtesy of FORD MOTOR CO.
  37. Install the coolant pump and the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    38. Fig 38: Identifying Coolant Pump Bolts Tightening Sequence
    GF0029305Courtesy of FORD MOTOR CO.
  38. Install the knock sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    39. Fig 39: Locating Knock Sensor (KS) Bolts
    GF0029287Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine coolant to the O-ring seals prior to installation.
  39. Using new O-ring seals, install the coolant tube.
    40. Fig 40: Identifying Coolant Tube
    GF0029286Courtesy of FORD MOTOR CO.
  40. 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 (15 lb-ft).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 90 degrees.
    41. Fig 41: Installing RH Cylinder Head Bolts In Sequence
    GF0029306Courtesy of FORD MOTOR CO.
  41. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    42. Fig 42: Identifying M6 Bolt
    GF0029244Courtesy of FORD MOTOR CO.
  42. 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 (15 lb-ft).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 90 degrees.
    43. Fig 43: Installing LH Cylinder Head Bolts In Sequence
    GF0029307Courtesy of FORD MOTOR CO.
  43. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    44. Fig 44: Identifying M6 Bolt
    GF0029260Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  44. Position the crankshaft dowel pin in the 9 o'clock position.
    45. Fig 45: Positioning Crankshaft Dowel Pin In 9 O'clock Position
    GF0029308Courtesy of FORD MOTOR CO.
    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.
  45. Install the valve tappets.
    46. Fig 46: Identifying Valve Tappets From Cylinder Head
    GF0029217Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  46. Position the camshafts onto the RH cylinder head in the neutral position as shown.
    47. Fig 47: Positioning Camshafts Onto RH Cylinder Head In Neutral Position
    GF0029309Courtesy of FORD MOTOR CO.
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
  47. Install the 8 camshaft caps and the 16 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    48. Fig 48: Installing Camshaft Caps & Bolts In Sequence
    GF0029310Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  48. Position the camshafts onto the LH cylinder head in the neutral position as shown.
    49. Fig 49: Positioning Camshafts Onto LH Cylinder Head In Neutral Position
    GF0029311Courtesy of FORD MOTOR CO.
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
  49. Install the 8 camshaft caps and the 16 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    50. Fig 50: Installing Camshaft Caps & Bolts In Sequence
    GF0029312Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  50. Using a feeler gauge, confirm that the valve tappet clearances are within specification. For additional information, refer to Valve Clearance Check .
    51. Fig 51: Measuring Valve Clearance
    GF0029313Courtesy of FORD MOTOR CO.
  51. Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    52. Fig 52: Locating RH Primary Timing Chain Guide Lower Bolt
    GF0029210Courtesy of FORD MOTOR CO.
  52. Install the RH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    53. Fig 53: Locating RH Secondary Timing Chain Tensioner & Bolts
    GF0029235Courtesy of FORD MOTOR CO.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  53. Rotate the RH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
    54. Fig 54: Installing Special Tool (303-1248) On Flats Of Camshafts
    GF0029314Courtesy of FORD MOTOR CO.
  54. 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.
    55. Fig 55: Aligning RH Exhaust Camshaft Sprocket & RH Secondary Timing Chain Colored Links With Timing Marks
    GF0029315Courtesy of FORD MOTOR CO.
  55. Position the RH secondary timing assembly onto the camshafts.
    56. Fig 56: Positioning RH Secondary Timing Assembly Onto Camshafts
    GF0029316Courtesy of FORD MOTOR CO.
  56. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. 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.
    57. Fig 57: Locating RH VCT Assembly Bolt & RH Exhaust Camshaft Sprocket Bolt
    GF0029208Courtesy of FORD MOTOR CO.
  57. Remove the lockpin from the RH secondary timing chain tensioner.
    58. Fig 58: Identifying Lock Pin On RH Secondary Timing Chain Tensioner
    GF0029317Courtesy of FORD MOTOR CO.
  58. Install the LH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    59. Fig 59: Locating LH Secondary Timing Chain Tensioner & Bolt
    GF0029259Courtesy of FORD MOTOR CO.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  59. Rotate the LH camshafts to the TDC position and install the special tool on the flats of the camshafts.
    60. Fig 60: Installing Special Tool (303-1248) On Flats Of Camshafts
    GF0029318Courtesy of FORD MOTOR CO.
  60. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
    • Align the colored links with the timing marks.
    61. Fig 61: Aligning LH Exhaust Camshaft Sprocket & LH Secondary Timing Chain Colored Links With Timing Marks
    GF0029319Courtesy of FORD MOTOR CO.
  61. Position the LH secondary timing assembly onto the camshafts.
    62. Fig 62: Positioning LH Secondary Timing Assembly Onto Camshafts
    GF0029320Courtesy of FORD MOTOR CO.
  62. Install the new VCT bolt and the exhaust camshaft bolt and the original washers. 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.
    63. Fig 63: Locating LH VCT Assembly Bolt & LH Exhaust Camshaft Sprocket Bolt
    GF0029205Courtesy of FORD MOTOR CO.
  63. Remove the lockpin from the LH secondary timing chain tensioner.
    64. Fig 64: Locating Lock Pin On LH Secondary Timing Chain Tensioner
    GF0029321Courtesy of FORD MOTOR CO.
  64. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
    65. Fig 65: Identifying Crankshaft Dowel Pin
    GF0029322Courtesy of FORD MOTOR CO.
  65. Install the crankshaft timing chain sprocket.
    66. Fig 66: Locating Crankshaft Timing Chain Sprocket
    GF0029202Courtesy of FORD MOTOR CO.
  66. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
    67. Fig 67: Aligning Timing Marks On VCT Assemblies & Crankshaft Sprocket
    GF0029323Courtesy of FORD MOTOR CO.
  67. Install the upper LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    68. Fig 68: Locating Upper LH Primary Timing Chain Guide Bolts
    GF0029203Courtesy of FORD MOTOR CO.
  68. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    69. Fig 69: Locating Lower LH Primary Timing Chain Guide Bolts
    GF0029200Courtesy of FORD MOTOR CO.
  69. Install the primary timing chain tensioner arm.
    70. Fig 70: Locating Primary Timing Chain Tensioner Arm
    GF0029199Courtesy of FORD MOTOR CO.
  70. 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.
    71. Fig 71: Compressing Plunger Using A Soft-Jawed Vise
    GF0029324Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
  71. Install the primary tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.
    72. Fig 72: Locating Primary Tensioner Bolts
    GF0029325Courtesy of FORD MOTOR CO.
  72. As a post-check, verify correct alignment of all timing marks.
    73. Fig 73: Verifying Correct Alignment Of All Timing Marks
    GF0029326Courtesy of FORD MOTOR CO.
  73. Install new VCT housing seals.
    74. Fig 74: Locating VCT Housing Seals
    GF0029197Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  74. Install the LH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    75. Fig 75: Identifying LH VCT Housing Bolts Tightening Sequence
    GF0029327Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  75. Install the RH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    76. Fig 76: Identifying RH VCT Housing Bolts Tightening Sequence
    GF0029328Courtesy of FORD MOTOR CO.
  76. Install the special tools.
    77. Fig 77: Identifying Special Tool (307-399)
    GF0029329Courtesy of FORD MOTOR CO.
    CAUTION: 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. Failure to follow this procedure can cause future oil leakage.
  77. 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.
    78. Fig 78: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover Sealing Surfaces
    GF0029330Courtesy of FORD MOTOR CO.
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  78. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
    79. Fig 79: Installing Engine Front Cover & Bolts In Sequence
    GF0029331Courtesy of FORD MOTOR CO.
  79. Remove the special tools (alignment pins).
    80. NOTE: Do not tighten the bolts at this time.
  80. Install the engine mount bracket and the 3 bolts.
    81. Fig 80: Locating Engine Mount Bracket & Bolts
    GF0029188Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  81. 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 (11 lb-ft).
    • 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).
    82. Fig 81: Identifying Tightening Of Engine Front Cover Bolts & Engine Mount Bracket Bolts In Sequence
    GF0029332Courtesy of FORD MOTOR CO.
  82. Install the 2 engine mount studs.
    • Tighten to 18 Nm (13 lb-ft).
    83. Fig 82: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  83. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    84. Fig 83: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
  84. Using the special tools, install a new crankshaft front seal.
    85. Fig 84: Installing Crankshaft Front Seal Using Special Tools (303-102) & (303-1251)
    GF0029107Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
  85. Using the special tools, install the crankshaft pulley.
    86. Fig 85: Installing Crankshaft Pulley
    GF0017018Courtesy of FORD MOTOR CO.
  86. Using the special tool, 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.
    87. Fig 86: Installing Crankshaft Pulley Washer & Bolt Using Special Tools (303-D055)
    GF0029104Courtesy of FORD MOTOR CO.
    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.
  87. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
    88. Fig 87: Installing VCT Solenoid And/Or Spark Plug Tube Seals Using Special Tools (205-153) & (303-1247/2)
    GF0029093Courtesy of FORD MOTOR CO.
    CAUTION: 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. Failure to follow this procedure can cause future oil leakage.
  88. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
    89. Fig 88: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-RH Cylinder Head Joints
    GF0029100Courtesy of FORD MOTOR CO.
  89. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    90. Fig 89: Installing RH Valve Cover Stud Bolts In Sequence
    GF0029101Courtesy of FORD MOTOR CO.
    CAUTION: 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. Failure to follow this procedure can cause future oil leakage.
  90. Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
    91. Fig 90: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-LH Cylinder Head Joints
    GF0029094Courtesy of FORD MOTOR CO.
  91. Using a new gasket, install the LH valve cover and 11 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    92. Fig 91: Installing LH Valve Cover Stud Bolts In Sequence
    GF0029095Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  92. Install the 6 coil-on-plug assemblies and the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
    93. Fig 92: Locating Coil-On-Plugs & Bolts
    GF0029180Courtesy of FORD MOTOR CO.
  93. 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).
    94. Fig 93: Locating Oil Filter Adapter & Bolts
    GF0029285Courtesy of FORD MOTOR CO.
    NOTE: Apply thread sealant with PTFE to the engine oil pressure (EOP) switch threads.
  94. Install the EOP switch.
    • Tighten to 18 Nm (13 lb-ft).
    95. Fig 94: Identifying EOP Switch
    GF0029284Courtesy of FORD MOTOR CO.
  95. Install the crankshaft position (CKP) sensor and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    96. Fig 95: Identifying CKP Sensor & Bolt
    GF0029271Courtesy of FORD MOTOR CO.
  96. Install LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    97. Fig 96: Locating LH CMP Sensor & Bolt
    GF0029258Courtesy of FORD MOTOR CO.
  97. Install and connect the CHT sensor jumper harness.
    98. Fig 97: Identifying CHT Sensor Jumper Harness
    GF0029243Courtesy of FORD MOTOR CO.
  98. Using new gaskets, install the lower intake manifold and the 10 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    99. Fig 98: Installing Lower Intake Manifold Bolts In Sequence
    GF0029084Courtesy of FORD MOTOR CO.
  99. Using a new gasket, install the thermostat housing and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    100. Fig 99: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
    GF0031413Courtesy of FORD MOTOR CO.
    CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower O-ring seals are not interchangeable.
  100. 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.
    101. Fig 100: Identifying Fuel Injector O-Ring Seals
    GF0029333Courtesy of FORD MOTOR CO.
  101. Install the fuel rail and injectors as an assembly and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
    102. Fig 101: Locating Fuel Rail And Injectors & Bolts
    GF0029240Courtesy of FORD MOTOR CO.
  102. Install the coolant bypass hose to the thermostat housing.
    103. Fig 102: Identifying Coolant By-Pass Hose
    GF0045683Courtesy of FORD MOTOR CO.
  103. Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    104. Fig 103: Locating RH CMP Sensor & Bolt
    GF0029239Courtesy of FORD MOTOR CO.
    NOTE: Align the bracket with the index mark made during removal.
  104. Install the upper intake manifold short support bracket and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    105. Fig 104: Identifying Bolt And Support Bracket
    GF0045682Courtesy of FORD MOTOR CO.
    NOTE: Align the bracket with the index mark made during removal.
  105. If equipped, install the upper intake long support manifold bracket and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    106. Fig 105: Locating Upper Intake Manifold Bracket & Bolt
    GF0029237Courtesy of FORD MOTOR CO.
  106. Install the engine lifting eye and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    107. Fig 106: Locating Engine Lifting Eye & Bolts
    GF0029236Courtesy of FORD MOTOR CO.
  107. Install the cover and the pin-type retainer.
    108. Fig 107: Locating Pin-Type Retainer & Cover
    GF0029282Courtesy of FORD MOTOR CO.
  108. Install the LH cylinder block drain plug.
    • Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
    109. Fig 108: Locating LH Cylinder Block Drain Plug
    GF0029231Courtesy of FORD MOTOR CO.
  109. Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten to 40 Nm (30 lb-ft).
    110. Fig 109: Locating RH Cylinder Block Drain Plug
    GF0029232Courtesy of FORD MOTOR CO.
  110. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
    111. Fig 110: Locating RH Exhaust Manifold Studs
    GF0029119Courtesy of FORD MOTOR CO.
    CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
  111. 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 (15 lb-ft).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    112. Fig 111: Installing RH Exhaust Manifold Nuts In Sequence
    GF0029120Courtesy of FORD MOTOR CO.
  112. Install the RH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (10 lb-ft).
    113. Fig 112: Locating RH Exhaust Manifold Heat Shield & Nuts
    GF0029233Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

  113. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    114. Fig 113: Identifying Nuts
    GF0045670Courtesy of FORD MOTOR CO.

    All vehicles 

  114. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
    115. Fig 114: Locating LH Exhaust Manifold Studs
    GF0029116Courtesy of FORD MOTOR CO.
    CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
  115. 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 (15 lb-ft).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    116. Fig 115: Installing LH Exhaust Manifold Nuts In Sequence
    GF0029334Courtesy of FORD MOTOR CO.
  116. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (10 lb-ft).
    117. Fig 116: Locating LH Exhaust Manifold Heat Shield & Nuts
    GF0029256Courtesy of FORD MOTOR CO.
  117. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
    • Tighten to 40 Nm (30 lb-ft).
    118. Fig 117: Locating LH Catalytic Converter Nuts
    GF0029230Courtesy of FORD MOTOR CO.
  118. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    119. Fig 118: Locating Accessory Drive Belt Tensioner Bolts
    GF0029185Courtesy of FORD MOTOR CO.
  119. Install the power steering pump and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    120. Fig 119: Identifying Bolts
    GF0045635Courtesy of FORD MOTOR CO.
  120. Install the power steering pressure (PSP) tube bracket and the bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
    121. Fig 120: Identifying Bolt
    GF0045680Courtesy of FORD MOTOR CO.
  121. Install the PSP tube bracket and nut to the RH valve cover stud bolt.
    • Tighten to 7 Nm (62 lb-in).
    122. Fig 121: Identifying Nut And PSP Tube Bracket
    GF0045679Courtesy of FORD MOTOR CO.
  122. Install the PSP tube bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    123. Fig 122: Identifying Bracket-To-Power Steering Pump Bolt
    GF0045634Courtesy of FORD MOTOR CO.
  123. Install the generator, the bolt and the nut.
    • Tighten to 48 Nm (35 lb-ft).
    124. Fig 123: Locating Generator, Bolts & Nuts
    GF0029250Courtesy of FORD MOTOR CO.
  124. Position the wiring harness onto the engine.
  125. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
    126. Fig 124: Locating Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Pin-Type Retainer
    GF0029278Courtesy of FORD MOTOR CO.
  126. Connect the generator electrical connector.
    127. Fig 125: Identifying Generator Electrical Connector
    GF0029248Courtesy of FORD MOTOR CO.
  127. Connect the generator B+ cable and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    128. Fig 126: Identifying Generator B+ Cable & Nut
    GF0029247Courtesy of FORD MOTOR CO.
  128. Connect the A/C compressor electrical connector.
    • Attach the A/C compressor wiring harness retainer.
    129. Fig 127: Identifying Connector And Retainer
    GF0045686Courtesy of FORD MOTOR CO.
  129. Connect the CKP sensor electrical connector.
    130. Fig 128: Identifying Crankshaft Position (CKP) Sensor Electrical Connector
    GF0029270Courtesy of FORD MOTOR CO.
  130. Install the wiring harness grommet.
    131. Fig 129: Identifying Wiring Harness Grommet
    GF0029277Courtesy of FORD MOTOR CO.
  131. Install the wiring harness retainer stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    132. Fig 130: Identifying Wiring Harness Retainer Stud Bolt
    GF0029276Courtesy of FORD MOTOR CO.
  132. Install the heat shield, the nut and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    133. Fig 131: Identifying Heat Shield, Nut & Bolt
    GF0029275Courtesy of FORD MOTOR CO.
  133. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  134. Connect the LH camshaft VCT solenoid electrical connector.
    135. Fig 132: Locating LH VCT Solenoid Electrical Connector
    GF0029178Courtesy of FORD MOTOR CO.
  135. Connect the 3 LH coil-on-plug electrical connectors.
    136. Fig 133: Locating LH Coil-On-Plug Electrical Connectors
    GF0029179Courtesy of FORD MOTOR CO.
  136. Connect the LH HO2S electrical connector.
    137. Fig 134: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029254Courtesy of FORD MOTOR CO.
  137. Connect the LH catalyst monitor sensor electrical connector.
    138. Fig 135: Identifying LH Catalyst Monitor Sensor Electrical Connector
    GF0041326Courtesy of FORD MOTOR CO.
  138. Connect the LH CMP sensor electrical connector.
    139. Fig 136: Locating LH CMP Sensor Electrical Connector
    GF0029253Courtesy of FORD MOTOR CO.
  139. Connect the CHT sensor electrical connector.
    140. Fig 137: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    GF0029227Courtesy of FORD MOTOR CO.
  140. Connect the 6 fuel injector electrical connectors (3 shown).
    141. Fig 138: Locating Fuel Injector Electrical Connectors
    GF0029226Courtesy of FORD MOTOR CO.
  141. Install the ground cable and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    142. Fig 139: Identifying Bolt
    GF0045681Courtesy of FORD MOTOR CO.
  142. Connect the KS electrical connector.
    143. Fig 140: Locating Knock Sensor (KS) Electrical Connector
    GF0029274Courtesy of FORD MOTOR CO.
  143. Connect the RH CMP sensor electrical connector.
    144. Fig 141: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
    GF0029224Courtesy of FORD MOTOR CO.
  144. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  145. If equipped, connect the heated PCV valve electrical connector.
    146. Fig 142: Locating Heated PCV Valve Electrical Connector
    GF0029177Courtesy of FORD MOTOR CO.
  146. Connect the 3 RH coil-on-plug electrical connectors.
    147. Fig 143: Locating RH Coil-On-Plug Electrical Connectors
    GF0029176Courtesy of FORD MOTOR CO.
  147. Connect the RH VCT solenoid electrical connector.
    148. Fig 144: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    GF0029175Courtesy of FORD MOTOR CO.
  148. Connect the RH HO2S electrical connector.
    149. Fig 145: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029222Courtesy of FORD MOTOR CO.

    FWD vehicles 

  149. Connect the RH catalyst monitor sensor electrical connector.
    150. Fig 146: Locating RH Catalyst Monitor Electrical Connector
    GF0029150Courtesy of FORD MOTOR CO.

    All vehicles 

  150. Connect the PSP switch electrical connector.
    151. Fig 147: Identifying PSP Connector
    GF0045633Courtesy of FORD MOTOR CO.
  151. Connect the fuel efficient power steering system solenoid electrical connector.
    152. Fig 148: Identifying Connector
    GF0045632Courtesy of FORD MOTOR CO.
  152. Using a new gasket, install the upper intake manifold and the 6 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    153. Fig 149: Installing Upper Intake Manifold Bolts In Sequence
    GF0029082Courtesy of FORD MOTOR CO.
  153. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer.
    • Tighten to 6 Nm (53 lb-in).
    154. Fig 150: Identifying Pin-Type Retainer And Fuel Tube Bracket Bolt
    GF0045678Courtesy of FORD MOTOR CO.
  154. Install the upper intake manifold short support bracket and the 2 bolts (1 shown).
    • Tighten to 10 Nm (89 lb-in).
    155. Fig 151: Identifying Upper Intake Manifold Support Bracket & Bolt
    GF0029335Courtesy of FORD MOTOR CO.
  155. If equipped, install the upper intake manifold long support bracket and the 2 bolts (1 shown).
    • Tighten the upper bolt 10 Nm (89 lb-in).
    • Tighten the lower bolt 24 Nm (18 lb-ft).
    156. Fig 152: Identifying Upper Intake Manifold Support Bracket & Bolts
    GF0029336Courtesy of FORD MOTOR CO.
  156. Attach the wiring harness retainers to the upper intake manifold.
    157. Fig 153: Locating Wiring Harness Retainers From Upper Intake Manifold
    GF0029170Courtesy of FORD MOTOR CO.
  157. Connect the throttle body (TB) electrical connector.
    158. Fig 154: Locating Throttle Body Electrical Connector
    GF0029169Courtesy of FORD MOTOR CO.
  158. Connect the PCV hose to the PCV valve.
    159. Fig 155: Identifying PCV Hose From PCV Valve
    GF0029168Courtesy of FORD MOTOR CO.
  159. If equipped, connect the heated PCV electrical connector.
    160. Fig 156: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
    GF0029167Courtesy of FORD MOTOR CO.
  160. If equipped, position the block heater wiring harness onto the engine and attach all of the harness retainers.
  161. If equipped, connect the block heater electrical connector and install the heat shield.
    162. Fig 157: Identifying Block Heater Wiring Harness
    GF0029221Courtesy of FORD MOTOR CO.
  162. Install the special tool on the LH cylinder head.
    163. Fig 158: Installing Special Tool (303-1245) On LH Cylinder Head
    GF0029161Courtesy of FORD MOTOR CO.
  163. Using the special tools, remove the engine from the stand.
    164. Fig 159: Removing Engine & Transaxle From Lift Table Using Special Tools (303-D089, 014-00071) & Suitable Engine Crane
    GF0029162Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
  164. Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
    165. Fig 160: Positioning Special Tool (303-1250) Onto End Of Crankshaft
    GF0029111Courtesy of FORD MOTOR CO.
  165. Using the special tools, install the new crankshaft rear seal.
    166. Fig 161: Installing New Crankshaft Rear Seal Using Special Tools (303-1250) & (205-153)
    GF0029112Courtesy of FORD MOTOR CO.
  166. Install the crankshaft sensor ring.
    167. Fig 162: Identifying Crankshaft Sensor Ring
    GF0029263Courtesy of FORD MOTOR CO.
  167. Install the flexplate and the 8 bolts.
    • Tighten to 80 Nm (59 lb-ft).
    168. Fig 163: Identifying Flexplate & Bolts
    GF0031416Courtesy of FORD MOTOR CO.
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