Section 1034 (Engine): Assembly: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Alignment Pins	307-399
Courtesy of FORD MOTOR CO.	Camshaft Alignment Tool	303-1248
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket	303-1245
Courtesy of FORD MOTOR CO.	Handle	205-153 (T80T-4000-W)
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Front Seal	303-1251
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Seal	303-1250
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper	303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Installer, Front Cover Oil Seal	303-335
Courtesy of FORD MOTOR CO.	Installer, Seal	303-1247/2
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Strap Wrench	303-D055 (D85L-6000-A)

Fig 1: Exploded View Of Engine Upper

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Engine Front

Courtesy of FORD MOTOR CO.

Fig 3: Exploded View Of Engine Lower

Courtesy of FORD MOTOR CO.

Fig 4: Exploded View Of LH Cylinder Head

Courtesy of FORD MOTOR CO.

Fig 5: Exploded View Of RH Cylinder Head

Courtesy of FORD MOTOR CO.

All vehicles 

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.
1. 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.
Fig 6: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Sealing Surface Of Crankshaft Rear Seal Retainer
Courtesy of FORD MOTOR CO.
2. Install the rear seal retainer and the 8 bolts.
   • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 7: Installing Crankshaft Rear Seal Retainer Bolts In Sequence
Courtesy of FORD MOTOR CO.
3. Install the oil pump and the 3 bolts.
   • Tighten to 10 Nm (89 lb-in).
Fig 8: Identifying Oil Pump & Bolts
Courtesy of FORD MOTOR CO.
4. 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).
Fig 9: Identifying Oil Pump Screen, Pickup Tube & Bolts
Courtesy 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.
5. Install the A/C compressor and the 2 bolts.
   • Tighten to 25 Nm (18 lb-ft).
Fig 10: Identifying A/C Compressor Bolts
Courtesy 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.
6. 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.
Fig 11: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Crankshaft Seal Retainer Plate-To-Cylinder Block
Courtesy 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.
7. 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: Installing Oil Pan Bolts 10, 11, 13 & 14 In Sequence
Courtesy of FORD MOTOR CO.
8. 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.
Fig 13: Aligning Oil Pan Flush With Rear Of Cylinder Block
Courtesy of FORD MOTOR CO.
9. Tighten bolts 10, 11, 13 and 14 in the sequence shown, to 3 Nm (27 lb-in).
Fig 14: Installing Oil Pan Bolts 10, 11, 13 & 14 In Sequence
Courtesy of FORD MOTOR CO.
10. 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 15: Installing Remaining Oil Pan Bolts In Sequence
Courtesy of FORD MOTOR CO.
11. 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).
Fig 16: Identifying A/C Compressor Nut & Stud
Courtesy of FORD MOTOR CO.
12. Install the coolant pump and the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 17: Identifying Coolant Pump Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
13. Install the knock sensor (KS) and the 2 bolts.
    • Tighten to 20 Nm (15 lb-ft).
Fig 18: Locating Knock Sensor (KS) Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine coolant to the O-ring seals prior to installation.
14. Using new O-ring seals, install the coolant tube.
Fig 19: Identifying Coolant Tube
Courtesy of FORD MOTOR CO.
15. 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.
Fig 20: Installing RH Cylinder Head Bolts In Sequence
Courtesy of FORD MOTOR CO.
16. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 21: Identifying M6 Bolt
Courtesy of FORD MOTOR CO.
17. 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.
Fig 22: Installing LH Cylinder Head Bolts In Sequence
Courtesy of FORD MOTOR CO.
18. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 23: Identifying M6 Bolt
Courtesy 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.
19. Position the crankshaft dowel pin in the 9 o'clock position.
Fig 24: Positioning Crankshaft Dowel Pin In 9 O'clock Position
Courtesy 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.
20. Install the valve tappets.
Fig 25: Identifying Valve Tappets From Cylinder Head
Courtesy 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.
21. Position the camshafts onto the RH cylinder head in the neutral position as shown.
Fig 26: Positioning Camshafts Onto RH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
22. Install the 8 camshaft caps and the 16 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 27: Installing Camshaft Caps & Bolts In Sequence
Courtesy 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.
23. Position the camshafts onto the LH cylinder head in the neutral position as shown.
Fig 28: Positioning Camshafts Onto LH Cylinder Head In Neutral Position
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
24. Install the 8 camshaft caps and the 16 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 29: Installing Camshaft Caps & Bolts In Sequence
Courtesy 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.
25. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check .
Fig 30: Measuring Valve Clearance
Courtesy of FORD MOTOR CO.
26. Install the RH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 31: Locating RH Primary Timing Chain Guide Lower Bolt
Courtesy of FORD MOTOR CO.
27. Install the RH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 32: Locating RH Secondary Timing Chain Tensioner & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
28. Rotate the RH camshafts to the top dead center (TDC) position and install the special tool on the flats of the camshafts.
Fig 33: Installing Special Tool (303-1248) On Flats Of Camshafts
Courtesy of FORD MOTOR CO.
29. 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.
Fig 34: Aligning RH Exhaust Camshaft Sprocket & RH Secondary Timing Chain Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
30. Position the RH secondary timing assembly onto the camshafts.
Fig 35: Positioning RH Secondary Timing Assembly Onto Camshafts
Courtesy of FORD MOTOR CO.
31. 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 36: Locating RH VCT Assembly Bolt & RH Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
32. Remove the lock pin from the RH secondary timing chain tensioner.
Fig 37: Identifying Lock Pin On RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
33. Install the LH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 38: Locating LH Secondary Timing Chain Tensioner & Bolt
Courtesy of FORD MOTOR CO.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
34. Rotate the LH camshafts to the TDC position and install the special tool on the flats of the camshafts.
Fig 39: Installing Special Tool (303-1248) On Flats Of Camshafts
Courtesy of FORD MOTOR CO.
35. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
    • Align the colored links with the timing marks.
Fig 40: Aligning LH Exhaust Camshaft Sprocket & LH Secondary Timing Chain Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
36. Position the LH secondary timing assembly onto the camshafts.
Fig 41: Positioning LH Secondary Timing Assembly Onto Camshafts
Courtesy of FORD MOTOR CO.
37. 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 42: Locating LH VCT Assembly Bolt & LH Exhaust Camshaft Sprocket Bolt
Courtesy of FORD MOTOR CO.
38. Remove the lock pin from the LH secondary timing chain tensioner.
Fig 43: Locating Lock Pin On LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
39. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
Fig 44: Identifying Crankshaft Dowel Pin
Courtesy of FORD MOTOR CO.
40. Install the crankshaft timing chain sprocket.
Fig 45: Locating Crankshaft Timing Chain Sprocket
Courtesy of FORD MOTOR CO.
41. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
Fig 46: Aligning Timing Marks On VCT Assemblies & Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
42. Install the upper LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 47: Locating Upper LH Primary Timing Chain Guide Bolts
Courtesy of FORD MOTOR CO.
43. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 48: Locating Lower LH Primary Timing Chain Guide Bolts
Courtesy of FORD MOTOR CO.
44. Install the primary timing chain tensioner arm.
Fig 49: Locating Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
45. 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 lock pin.
Fig 50: Compressing Plunger Using A Soft-Jawed Vise
Courtesy 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.
46. Install the primary tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the lock pin.
Fig 51: Locating Primary Tensioner Bolts
Courtesy of FORD MOTOR CO.
47. As a post-check, verify correct alignment of all timing marks.
Fig 52: Verifying Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
48. Install new VCT housing seals.
Fig 53: Locating VCT Housing Seals
Courtesy 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.
49. Install the LH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 54: Identifying LH VCT Housing Bolts Tightening Sequence
Courtesy 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.
50. Install the RH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 55: Identifying RH VCT Housing Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
51. Install the special tools.
Fig 56: Identifying Special Tool (307-399)
Courtesy 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.
52. 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.
Fig 57: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover Sealing Surfaces
Courtesy of FORD MOTOR CO.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
53. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
Fig 58: Installing Engine Front Cover & Bolts In Sequence
Courtesy of FORD MOTOR CO.
54. Remove the special tools (alignment pins).
NOTE: Do not tighten the bolts at this time.
55. Install the engine mount bracket and the 3 bolts.
Fig 59: Locating Engine Mount Bracket & Bolts
Courtesy 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.
56. 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).
Fig 60: Identifying Tightening Of Engine Front Cover Bolts & Engine Mount Bracket Bolts In Sequence
Courtesy of FORD MOTOR CO.
57. Install the 2 engine mount studs.
    • Tighten to 18 Nm (13 lb-ft).
Fig 61: Locating Engine Mount Studs
Courtesy of FORD MOTOR CO.
58. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
Fig 62: Locating Engine Mount Bracket & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
59. Using the special tools, install a new crankshaft front seal.
Fig 63: Installing Crankshaft Front Seal Using Special Tools (303-102) & (303-1251)
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
60. Using the special tools, install the crankshaft pulley.
Fig 64: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
61. 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.
Fig 65: Installing Crankshaft Pulley Washer & Bolt Using Special Tools (303-D055)
Courtesy 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.
62. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
Fig 66: Installing VCT Solenoid And/Or Spark Plug Tube Seals Using Special Tools (205-153) & (303-1247/2)
Courtesy 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.
63. 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.
Fig 67: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-RH Cylinder Head Joints
Courtesy of FORD MOTOR CO.
64. 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).
Fig 68: Installing RH Valve Cover Stud Bolts In Sequence
Courtesy 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.
65. 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.
Fig 69: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-LH Cylinder Head Joints
Courtesy of FORD MOTOR CO.
66. Using a new gasket, install the LH valve cover and 11 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 70: Installing LH Valve Cover Stud Bolts In Sequence
Courtesy of FORD MOTOR CO.
67. Install the wiring harness retaining bracket and the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
Fig 71: Identifying Wiring Harness Retaining Bracket & Nuts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
68. Install the 6 coil-on-plug assemblies and the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
Fig 72: Locating Coil-On-Plugs & Bolts
Courtesy of FORD MOTOR CO.
69. 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).
Fig 73: Locating Oil Filter Adapter & Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply pipe sealant with Teflon® to the engine oil pressure (EOP) switch threads.
70. Install the EOP switch.
    • Tighten to 18 Nm (13 lb-ft).
Fig 74: Identifying EOP Switch
Courtesy of FORD MOTOR CO.
71. Install the crankshaft position (CKP) sensor and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 75: Identifying CKP Sensor & Bolt
Courtesy of FORD MOTOR CO.
72. Install LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 76: Locating LH CMP Sensor & Bolt
Courtesy of FORD MOTOR CO.
73. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
Fig 77: Identifying CHT Sensor Jumper Harness
Courtesy of FORD MOTOR CO.
74. Using new gaskets, install the lower intake manifold and the 10 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 78: Installing Lower Intake Manifold Bolts In Sequence
Courtesy of FORD MOTOR CO.
75. Using a new gasket, install the thermostat housing and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 79: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
Courtesy 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.
76. 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.
Fig 80: Identifying Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
77. Install the fuel rail and injectors as an assembly and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 81: Locating Fuel Rail And Injectors & Bolts
Courtesy of FORD MOTOR CO.

All wheel drive (AWD) vehicles 

78. Install the catalytic converter bracket and the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 82: Locating Catalytic Converter Bracket & Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

79. Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 83: Locating RH CMP Sensor & Bolt
Courtesy of FORD MOTOR CO.
80. Install the engine lifting eye and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
Fig 84: Locating Engine Lifting Eye & Bolts
Courtesy of FORD MOTOR CO.
81. Install the cover and the pin-type retainer.
Fig 85: Locating Pin-Type Retainer & Cover
Courtesy of FORD MOTOR CO.
82. Install the LH cylinder block drain plug.
    • Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
Fig 86: Locating LH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
83. Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten to 40 Nm (30 lb-ft).
Fig 87: Locating RH Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
84. Install 6 new RH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 88: Locating RH Exhaust Manifold Studs
Courtesy 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.
85. 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).
Fig 89: Installing RH Exhaust Manifold Nuts In Sequence
Courtesy of FORD MOTOR CO.

Front wheel drive (FWD) vehicles 

86. Using a new gasket, install the RH catalytic converter and the 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 90: Locating RH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.

All vehicles 

87. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
Fig 91: Locating LH Exhaust Manifold Studs
Courtesy 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.
88. 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).
Fig 92: Installing LH Exhaust Manifold Nuts In Sequence
Courtesy of FORD MOTOR CO.
89. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (10 lb-ft).
Fig 93: Locating LH Exhaust Manifold Heat Shield & Nuts
Courtesy of FORD MOTOR CO.
90. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
    • Tighten to 40 Nm (30 lb-ft).
Fig 94: Locating LH Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
91. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 95: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
92. Install the power steering pump and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 96: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
93. Install the power steering pressure (PSP) tube bracket and bolt to the RH cylinder head.
    • Tighten to 10 Nm (89 lb-in).
Fig 97: Identifying Power Steering Pressure (PSP) Tube & Bracket Assembly
Courtesy of FORD MOTOR CO.
94. Install the PSP hose bracket nut.
    • Tighten to 9 Nm (80 lb-in).
Fig 98: Identifying PSP Hose Bracket Nut
Courtesy of FORD MOTOR CO.
95. Attach the PSP hose retainer to the engine lifting eye.
Fig 99: Locating PSP Hose Retainer From Engine Lifting Eye
Courtesy of FORD MOTOR CO.
96. Install the generator, the nut and the bolt.
    • Tighten to 48 Nm (35 lb-ft).
Fig 100: Locating Generator, Bolts & Nuts
Courtesy of FORD MOTOR CO.
97. Using new O-ring seals, install the A/C manifold and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 101: Locating A/C Manifold Bolt
Courtesy of FORD MOTOR CO.
98. Position the wiring harness onto the engine.
99. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.
Fig 102: Locating Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
100. Attach the wiring harness retainer to the generator.
Fig 103: Identifying Wiring Harness Retainer From Generator
Courtesy of FORD MOTOR CO.
101. Connect the generator electrical connector.
Fig 104: Identifying Generator Electrical Connector
Courtesy of FORD MOTOR CO.
102. Connect the generator B+ cable and install the nut.
     • Tighten to 6 Nm (53 lb-in).
Fig 105: Identifying Generator B+ Cable & Nut
Courtesy of FORD MOTOR CO.
103. Connect the A/C compressor electrical connector.
Fig 106: Identifying A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
104. Connect the CKP sensor electrical connector.
Fig 107: Identifying Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
105. Install the wiring harness grommet.
Fig 108: Identifying Wiring Harness Grommet
Courtesy of FORD MOTOR CO.
106. Install the wiring harness retainer stud bolt.
     • Tighten to 10 Nm (89 lb-in).
Fig 109: Identifying Wiring Harness Retainer Stud Bolt
Courtesy of FORD MOTOR CO.
107. Install the heat shield, the nut and the bolt.
     • Tighten to 10 Nm (89 lb-in).
Fig 110: Identifying Heat Shield, Nut & Bolt
Courtesy of FORD MOTOR CO.
108. Install the wiring harness retainer bolt on the rear of the LH cylinder head.
     • Tighten to 10 Nm (89 lb-in).
Fig 111: Identifying Wiring Harness Retainer Bolt From Rear Of LH Cylinder Head
Courtesy of FORD MOTOR CO.
109. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
110. Connect the LH camshaft VCT solenoid electrical connector.
Fig 112: Locating LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
111. Connect the 3 LH coil-on-plug electrical connectors.
Fig 113: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
112. Connect the LH HO2S electrical connector.
Fig 114: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
113. Connect the LH catalyst monitor sensor electrical connector.
Fig 115: Identifying LH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
114. Connect the LH CMP sensor electrical connector.
Fig 116: Locating LH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
115. Connect the CHT sensor electrical connector.
Fig 117: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
116. Connect the 6 fuel injector electrical connectors (3 shown).
Fig 118: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
117. Connect the KS electrical connector.
Fig 119: Locating Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
118. Connect the RH CMP sensor electrical connector.
Fig 120: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
119. Connect the coolant bypass hose to the thermostat housing.
Fig 121: Identifying Coolant Bypass Hose From Thermostat Housing
Courtesy of FORD MOTOR CO.
120. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
121. If equipped, connect the heated PCV valve electrical connector.
Fig 122: Locating Heated PCV Valve Electrical Connector
Courtesy of FORD MOTOR CO.
122. Connect the 3 RH coil-on-plug electrical connectors.
Fig 123: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
123. Connect the RH VCT solenoid electrical connector.
Fig 124: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.

FWD vehicles 

124. Connect the RH catalyst monitor sensor electrical connector.
Fig 125: Locating RH Catalyst Monitor Electrical Connector
Courtesy of FORD MOTOR CO.

All vehicles 

125. Connect the PSP switch electrical connector.
Fig 126: Locating PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
126. Using new gaskets, install the upper intake manifold and the 6 bolts.
     • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 127: Installing Upper Intake Manifold Bolts In Sequence
Courtesy of FORD MOTOR CO.
127. Install the upper intake manifold short support bracket and the 2 bolts (one shown).
     • Tighten to 10 Nm (89 lb-in).
Fig 128: Identifying Upper Intake Manifold Support Bracket & Bolt
Courtesy of FORD MOTOR CO.
128. If equipped, install the upper intake manifold long support bracket and the 2 bolts (one shown).
     • Tighten the upper bolt 10 Nm (89 lb-in).
     • Tighten the lower bolt 24 Nm (18 lb-ft).
Fig 129: Identifying Upper Intake Manifold Support Bracket & Bolts
Courtesy of FORD MOTOR CO.
129. Install the RH exhaust manifold heat shield and the 3 bolts.
     • Tighten to 14 Nm (10 lb-ft).
Fig 130: Locating RH Exhaust Manifold Heat Shield & Nuts
Courtesy of FORD MOTOR CO.
130. Connect the RH HO2S electrical connector.
Fig 131: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
131. Attach the wiring harness retainers to the upper intake manifold.
Fig 132: Locating Wiring Harness Retainers From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
132. Connect the throttle body (TB) electrical connector.
Fig 133: Locating Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
133. Connect the PCV hose to the PCV valve.
Fig 134: Identifying PCV Hose From PCV Valve
Courtesy of FORD MOTOR CO.
134. If equipped, connect the heated PCV electrical connector.
Fig 135: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
Courtesy of FORD MOTOR CO.
135. If equipped, position the block heater wiring harness onto the engine.
     • Attach the block heater wiring harness retainer to the power steering reservoir hose and the PSP hose.
Fig 136: Identifying Block Heater Wiring Harness From Engine
Courtesy of FORD MOTOR CO.
136. If equipped, connect the block heater electrical connector and install the heat shield.
Fig 137: Identifying Block Heater Wiring Harness
Courtesy of FORD MOTOR CO.
137. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
Fig 138: Identifying Block Heater Wiring Harness Retainer From Upper Intake Manifold
Courtesy of FORD MOTOR CO.
138. Install the special tool on the LH cylinder head.
Fig 139: Installing Special Tool (303-1245) On LH Cylinder Head
Courtesy of FORD MOTOR CO.
139. Using the special tools, remove the engine from the stand.
Fig 140: Removing Engine & Transaxle From Lift Table Using Special Tools (303-D089, 014-00071) & Suitable Engine Crane
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
140. Position the special tool onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
Fig 141: Positioning Special Tool (303-1250) Onto End Of Crankshaft
Courtesy of FORD MOTOR CO.
141. Using the special tools, install the new crankshaft rear seal.
Fig 142: Installing New Crankshaft Rear Seal Using Special Tools (303-1250) & (205-153)
Courtesy of FORD MOTOR CO.
142. Install the crankshaft sensor ring.
Fig 143: Identifying Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.
143. Install the flexplate and the 8 bolts.
     • Tighten to 80 Nm (59 lb-ft).
Fig 144: Identifying Flexplate & Bolts
Courtesy of FORD MOTOR CO.