Section 1084 (Engine - 3.5L ECOBOOST (272KW/370PS)): Assembly: Engine
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C)Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 205-142 (T80T-4000-J)Installer, Differential Bearing Cone | |
| 205-149 (T80T-4000-R)Installer, Spindle Bearing | |
| 205-153 (T80T-4000-W)Handle | |
| 303-102Installer, Crankshaft Pulley | |
| 303-1246Engine Spreader Bar, TKIT-2006UF-FLM, TKIT-2006UF-ROW | |
| 303-1247VCT Spark Plug Tube Seal Remover and Installer, TKIT-2006UF-FLM, TKIT-2006UF-ROW | |
| 303-1251Installer, Front Seal, TKIT-2006UF-FLM, TKIT-2006UF-ROW | |
| 303-1633Remover, Roller Rocker Follower, TKIT-2014D-ROW3, TKIT-2014D-FL_ROW | |
| 303-1633-01Remover, Roller Rocker Follower | |
| 303-1654Lift Eyes | |
| 303-1655Tool, Camshaft Holding | |
| 303-1663Installer, VDOP Seal | |
| 307-399Alignment Pins, Transmission Fluid Pump, TKIT-2002N-DEW, TKIT-2000AP-FLM/LM | |
| Strap Wrench | |
| Floor Crane | |
| Mounting Stand | |
| Hose Clamp Remover/Installer | |
| Round-Ended Steel Rule | |
| Piston Ring Compressor |
Materials
| Name | Specification |
|---|---|
| Motorcraft® High Performance Engine RTV SiliconeTA-357 | WSE-M4G323-A6 |
| Motorcraft® Silicone Gasket RemoverZC-30-A | - |
| Motorcraft® Orange Prediluted Antifreeze/CoolantVC-3DIL-B | WSS-M97B44-D2 |
| Motorcraft® Metal Surface Prep WipesZC-31-B | - |
| Engine Oil - SAE 5W-30 - Synthetic Blend Motor OilXO-5W30-Q1SP | WSS-M2C946-B1 |
| Motorcraft® Yellow Prediluted Antifreeze/CoolantVC-13DL-G | WSS-M97B57-A2 |
| Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B | - |
- Install the piston cooling jets and bolts into the cylinder block.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 30°
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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.
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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.
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NOTE: This chart is for selecting main bearings 1 and 4 only.
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NOTE: This chart is continued in the next step.NOTE: This chart is for selecting main bearings 2 and 3 only.
- Main housing bore diameter.
- Crankshaft diameter.
- 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.
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NOTE: This chart is for selecting main bearings 2 and 3 only.
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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.
Torque:
Stage 1: 17 lb.ft (23 Nm)
Stage 2: 32 lb.ft (43 Nm)
Stage 3: 90°
- Measure the connecting rod large end bore in 2 directions.
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- Remove the bolts and the rod cap.
- Discard the bolts.
- Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
- Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
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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 in the cylinder block.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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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.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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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.
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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.
- Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- 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.
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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.
- 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.
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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.
Torque:Stage 1: 20 lb.ft (27 Nm)Stage 2: 180°
- Install the new main bearing cap side bolts.
Torque:
Stage 1: 33 lb.ft (45 Nm)
Stage 2: 90°
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- Position the crankshaft to the rear of the cylinder block.Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Zero the Dial Indicator Gauge.
- Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
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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.
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NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston.NOTE: The arrow on the top of the piston indicates the front of the engine.
- Center line of the piston parallel to the wrist pin bore.
- Upper compression ring gap location.
- Upper oil control segment ring gap location.
- Lower oil control segment ring gap location.
- Lower compression ring gap location.
- Spacer oil control ring gap location.
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NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Be sure not to damage or bend the piston oil cooling jets when seating the connecting rod on the crankshaft journal. Push the piston down until the connecting rod bearing seats on the crankshaft journal.NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.NOTE: Make sure the piston rings are positioned to specifications for installation. Refer to Piston and Connecting Rod .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. Repeat until all 6 piston assemblies are installed. Use the General Equipment: Piston Ring Compressor.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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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 the new bolts.
Torque:
Stage 1: 17 lb.ft (23 Nm)
Stage 2: 32 lb.ft (43 Nm)
Stage 3: 90°
- Install the main bearing cap support brace and the new bolts.
Torque:
Stage 1: 20 lb.ft (27 Nm)
Stage 2: 225°
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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.
- Lubricate the crankshaft rear seal with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the crankshaft rear seal retainer and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
- Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.
- Install the oil pump and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
- Install a new oil pump screen and pickup tube O-ring seal.
- Install the oil pump screen and pickup tube and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
Vehicles with late build oil pan
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
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.
- Install the oil pan and bolts.
Torque:Stage 1: 27 lb.in (3 Nm)Stage 2: Loosen:: 180°
- Using a straight edge, align the oil pan flush with the rear of the cylinder block at the 2 areas shown. Use the General Equipment: Round-Ended Steel Rule.
- Tighten the bolts in the sequence.
Torque: 27 lb.in (3 Nm)
- Install the remaining oil pan bolts. Tighten in the sequence shown.
Torque:
Stage 1: Tighten bolts 1-9 and 11-14 to: 177 lb.in (20 Nm)
Stage 2: Tighten bolts 1-9 and 11-14 an additional: 45°
Stage 3: Tighten bolt 10 to: 177 lb.in (20 Nm)
Stage 4: Tighten bolt 10 an additional: 45°
Stage 5: Tighten bolts 15 and 16 to: 89 lb.in (10 Nm)
Stage 6: Tighten bolts 15 and 16 an additional: 90°
Vehicles with early build oil pan
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NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
Apply a 5.5 mm bead of Motorcraft® High Performance Engine RTV Silicone to the 2 engine front cover-to-cylinder block joint areas.
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NOTE: The engine block skirt stiffener and the bolts must be installed with 4 minutes of sealant application. Final tightening of the engine block skirt stiffener bolts must be carried out within 60 minutes of sealant application.
Apply a 4.0 mm (0.16) bead of Motorcraft® High Performance Engine RTV Silicone to the engine block skirt stiffener.
Material
: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 5.5 mm 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 engine block skirt stiffener.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the engine block skirt stiffener and bolts.
- Using a straight edge, align the engine block skirt stiffener flush with the rear of the cylinder block at the 2 areas shown.
- Tighten the bolts in the sequence.
Torque: 27 lb.in (3 Nm)
- Install the remaining engine block skirt stiffener bolts. Tighten in the sequence shown.
Torque:
Stage 1: 1 thru 14 : 177 lb.in (20 Nm)
Stage 2: 15 thru 16 : 89 lb.in (10 Nm)
Stage 3: 1 thru 9 : 45°
Stage 4: 10: 90°
Stage 5: 11 thru 16 : 45°
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NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Install the two guide studs.
- Make sure that the mating faces of the new oil pan is clean and free of foreign material.
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NOTE: The oil pan must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application and the bolts must be installed and tighten to 2-5 Nm (18-44 in-lbs) within 15 minutes of applying the sealant. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.
Apply a 4 mm (0.16 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: It will be necessary to remove the guide studs before installing the remaining bolts.
Install the oil pan and the bolts. Tighten in sequence shown.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
All vehicles
- Install the channel cover plate and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
- Install the KS and the bolts.
Torque: 177 lb.in (20 Nm)
- Install the LH cylinder head gasket.
- Install the LH cylinder head and the new bolts.
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 33 lb.ft (45 Nm)
Stage 3: 90°
Stage 4: 90°
Stage 5: 90°
- Install the LH M6 bolt.
Torque: 89 lb.in (10 Nm)
- Install the RH cylinder head gasket.
- Install the RH cylinder head and the new bolts.
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 33 lb.ft (45 Nm)
Stage 3: 90°
Stage 4: 90°
Stage 5: 90°
- Install the RH M6 bolt.
Torque: 89 lb.in (10 Nm)
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NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.NOTE: If the original hydraulic lash adjusters are to be reinstalled, they must be installed in their original locations.NOTE: RH shown, LH similar.
- Lubricate the hydraulic lash adjusters with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the hydraulic lash adjusters.
- Lubricate the hydraulic lash adjusters with clean engine oil.
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NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed. 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.
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NOTE: Coat the camshafts with clean engine oil prior to installation.
Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the RH camshaft seals gaps as shown.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- Install camshaft bearing caps and the bolts.
- Install camshaft bearing mega caps and the bolts.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 45°
- Rotate the RH camshafts to TDC.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1655 Tool, Camshaft Holding.
- Position the RHVCT units onto the camshafts.
- Install the new RHVCT unit bolts.
Torque:
Stage 1: 30 lb.ft (40 Nm)
Stage 2: Loosen:: 1turn(s)
Stage 3: 18 lb.ft (25 Nm)
Stage 4: 150°
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NOTE: Coat the camshafts with clean engine oil prior to installation.
Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the LH camshaft seals gaps as shown.
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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- Install camshaft bearing caps and the bolts.
- Install camshaft bearing mega caps and the bolts.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 45°
- Rotate the LH camshafts to TDC.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.
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NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 303-1655 Tool, Camshaft Holding.
- Position the LHVCT units onto the camshafts.
- Install the new LHVCT unit bolts.
Torque:
Stage 1: 30 lb.ft (40 Nm)
Stage 2: Loosen:: 1turn(s)
Stage 3: 18 lb.ft (25 Nm)
Stage 4: 150°
- Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
- Install the crankshaft sprocket.
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NOTE: The crankshaft sprocket is reversible with a timing mark on each face. For installation of each timing chain, utilize the timing mark on the front face of the crankshaft sprocket for chain alignment.
- Install the LH timing chain with the single colored links aligned with the timing marks on the VCT units.
- Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
- Install the LH timing chain tensioner arm.
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- Position the tensioner in a soft-jawed vise.
- Using pliers, squeeze the ends of the ratchet wire clip together.
- Using the soft-jawed vise, compress the plunger to the reset position.
- Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.
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- Position the LH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
- Install the retainers.
Torque: 89 lb.in (10 Nm)
- Remove the pin.
- Install the LH timing chain guide and the bolts.
Torque: 89 lb.in (10 Nm)
- Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.
- Install Special Service Tool: 303-1655 Tool, Camshaft Holding.
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NOTE: The crankshaft sprocket is reversible with a timing mark on each face. For installation of each timing chain, utilize the timing mark on the front face of the crankshaft sprocket for chain alignment.
- Install the RH timing chain with the single colored links aligned with the timing marks on the VCT units.
- Install the double colored links so they straddle the timing mark on the crankshaft sprocket.
- Install the RH timing chain tensioner arm.
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- Position the tensioner in a soft-jawed vise.
- Using pliers, squeeze the ends of the ratchet wire clip together.
- Using the soft-jawed vise, compress the plunger to the reset position.
- Install a locking pin in the 2 holes of the tensioner body to hold the plunger in place.
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- Position the RH timing chain tensioner with the end of the tensioner correctly engaged to the tensioner arm.
- Install the retainers.
Torque: 89 lb.in (10 Nm)
- Remove the pin.
- Install the RH timing chain guide and the bolts.
Torque: 89 lb.in (10 Nm)
- Remove Special Service Tool: 303-1655 Tool, Camshaft Holding.
- Using the special tools, install the front cover to coolant pipe seal.Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.
- Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
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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 the 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover 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.
Apply a 4.0 mm (0.16 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- 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 places as indicated.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: Make sure the locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and the bolts.
Torque: 27 lb.in (3 Nm)
- Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.
- Install the remaining engine front cover bolts.
Torque:Stage 1: Tighten bolts 1 thru 24 to: 177 lb.in (20 Nm)Stage 2: Tighten bolts 1 thru 24 to: 45°
- With clean oil, lubricate and position the oil pump electrical connector seal.
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NOTE: If the oil pump electrical connector seal is not properly installed, it may result in oil leakage.
Using the special tool, install the oil pump electrical connector seal.Install Special Service Tool: 303-1663 Installer, VDOP Seal.
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NOTE: The front surface of the oil pump electrical connector seal will be level with the engine front cover recess.
Inspect the oil pump electrical connector seal for proper installation.
- Lubricate the crankshaft front seal bore with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Using the special tools, install the crankshaft front seal. Use Special Service Tool: 303-102 Installer, Crankshaft Pulley., 303-1251 Installer, Front Seal.
- Lubricate the crankshaft front seal and the crankshaft pulley with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Using the special tool, install the crankshaft pulley.Use Special Service Tool: 303-102 Installer, Crankshaft Pulley.
- Install the new crankshaft bolt and the washer. Use the General Equipment: Strap Wrench.
Torque:
Stage 1: 37 lb.ft (50 Nm)
Stage 2: 90°
Stage 3: 60°
- Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.
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- Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower., 303-1633-01 Remover, Roller Rocker Follower.
- Turn the knob on the special tool clockwise to depress the valve and spring.
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- Lubricate the camshaft roller follower with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the camshaft roller follower.
- Assemble the camshaft roller follower spring clip onto the hydraulic lash adjuster.
- Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower., 303-1633-01 Remover, Roller Rocker Follower.
- Repeat steps for the remaining camshaft roller followers.
- Lubricate the camshaft roller follower with clean engine oil.
- Remove the bolts and the camshaft bearing caps.
- Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.
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- Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower., 303-1633-01 Remover, Roller Rocker Follower.
- Turn the knob on the special tool clockwise to depress the valve and spring.
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- Lubricate the camshaft roller follower with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the camshaft roller follower.
- Assemble the camshaft roller follower spring clip onto the hydraulic lash adjuster.
- Turn the knob on the special tool counterclockwise to raise the valve and spring.Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower., 303-1633-01 Remover, Roller Rocker Follower.
- Repeat steps for the remaining camshaft roller followers.
- Lubricate the camshaft roller follower with clean engine oil.
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- Install camshaft bearing caps and the bolts.
- Install camshaft bearing mega caps and the bolts.
Torque:Stage 1: 71 lb.in (8 Nm)Stage 2: 45°
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NOTE: Use Motorcraft® Orange Antifreeze/Coolant for vehicles built up to 08-July-2018 and Motorcraft® Yellow Antifreeze/Coolant for vehicles built from 09-July-2018. Failure to use the correct coolant can degrade corrosion protection.
Install a new coolant pump gasket and lubricate the O-ring seal with clean engine coolant.
Material: Motorcraft® Orange Prediluted Antifreeze/Coolant / VC-3DIL-B (WSS-M97B44-D2)
Material: Motorcraft® Yellow Prediluted Antifreeze/Coolant / VC-13DL-G (WSS-M97B57-A2)
- Install the coolant pump and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
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NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
Install the CMP sensors and the bolts.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
Torque: 71 lb.in (8 Nm)
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NOTE: Installation of new seals is only required if damaged seals were removed.NOTE: RH shown, LH similar.
If removed, using the special tools, install the spark plug tube seals.Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.
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NOTE: Installation of new seals is only required if damaged seals were removed.NOTE: RH shown, LH similar.
If removed, using the special tools, install the VCT oil control solenoid seals.Use Special Service Tool: 205-142 (T80T-4000-J) Installer, Differential Bearing Cone., 205-153 (T80T-4000-W) Handle.
- Install the new valve cover and intake port gaskets.
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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.
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.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the RH valve cover and the fasteners.
Torque: 89 lb.in (10 Nm)
- Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
- Install the new valve cover and intake port gaskets.
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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.
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.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Install the LH valve cover and the fasteners.
Torque: 89 lb.in (10 Nm)
- Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
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NOTE: Apply clean engine oil to the CMP sensor O-ring seals.
Install the CMP sensors and the bolts.
Material
: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
Torque: 71 lb.in (8 Nm)
- Install all of the ignition coil-on-plugs and the bolts.
Torque:
Stage 1: 62 lb.in (7 Nm)
Stage 2: 50 °
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- Install the engine wiring harness and attach the wire harness retainers.
- Connect the ignition coil-on-plug electrical connectors.
- Connect the VCT oil control solenoid electrical connectors.
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- Attach the wire harness retainers.
- Connect the ignition coil-on-plug electrical connectors.
- Connect the CMP sensor electrical connectors.
- Connect the VCT oil control solenoid electrical connectors.
- Install the oil level indicator.
- Connect the oil control solenoid electrical connector and attach the wire harness retainers.
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- Install the CKP sensor and bolt.
Torque: 62 lb.in (7 Nm)
- Connect the CKP sensor electrical connector.
- Install the CKP sensor and bolt.
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- Attach the wiring harness grommet to the cylinder block.
- Install the studbolt.
Torque: 89 lb.in (10 Nm)
- Install the nut, bolt and the heat shield.
Torque: 89 lb.in (10 Nm)
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- Install the ground strap and the studbolt. Connect the wire retainer.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 20°
- Position back the body ground strap and install the bolt.
Torque: 97 lb.in (11 Nm)
- Install the ground strap and the studbolt. Connect the wire retainer.
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- Connect the RH and LH direct injection fuel rail electrical connectors.
- Connect the RH and LH port injection fuel rail electrical connectors.
- Connect the KS electrical connector.
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- Install the ground wire and the studbolt and attach the wire harness retainer.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 20°
- Connect the CMP sensor electrical connectors.
- Connect the CHT sensor electrical connector.
- Install the ground wire and the studbolt and attach the wire harness retainer.
- Install the heat shield, bolt and studbolt.
Torque: 89 lb.in (10 Nm)
- Install the RH block coolant drain plug.
Torque:
Stage 1: 142 lb.in (16 Nm)
Stage 2: 180°
- Install the LH block drain plug or block heater.
Torque: 30 lb.ft (40 Nm)
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NOTE: Tighten the upper bolts first.
Install the oil filter adapter and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
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NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
Install the new oil cooler and the bolt.
Torque:
Stage 1: 43 lb.ft (58 Nm)
Stage 2: 9 °
- Connect the EOP sensor electrical connector and the wire harness retainer.
- Install the generator stud bolt.
Torque: 71 lb.in (8 Nm)
- Install the generator, nut and bolt.
Torque: 35 lb.ft (48 Nm)
- Install the CAC tube bracket and the nuts.
Torque: 53 lb.in (6 Nm)
- Lubricate the new TC fitting and oil filter assembly O-ring seal with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install and tighten the new LHTC fitting and oil filter assembly into the engine block.
Torque: 35 lb.ft (48 Nm)
- Install the new TC gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.
- If a TC cooling tube was separated, then replace the separated TC cooling tube rubber gaskets. After installing the rubber gasket, lubricate with clean engine coolant.
- Install the new TC coolant supply tube and the new TC coolant return tube O-ring seals. Lubricate the new O-ring seal with clean engine coolant.
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NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bores. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.NOTE: Install the coolant tubes with the TC.
Install the LHTC and tighten the retainers in the following 2 stages.
Torque:
Stage 1: Tighten 1-3 in the sequence shown to : 24 lb.ft (32 Nm)
Stage 2: Re-tighten 1 to : 24 lb.ft (32 Nm)
- Install the LHTC coolant supply tube and bolt.
Torque:Stage 1: 89 lb.in (10 Nm)Stage 2: 30°
- Lubricate the new LHTC oil return tube O-ring seals with clean engine oil.
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NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger and engine O-ring bores. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.NOTE: Fully seat the TC oil return tube into the turbocharger and engine bore holes flush to 2.5 mm off the mounting surface prior to fastener rundown.
Install the new LHTC oil return tube, then install and tighten the TC oil return tube bolts.
Torque:
Stage 1: 66 lb.ft (89 Nm)
Stage 2: 30°
- Lubricate the new LHTC oil supply tube O-ring seal with clean engine oil.
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NOTE: Use brake cleaner on a lint free rag to remove the O-ring residue out of the TC tube to TC turbocharger O-ring bore. Inspect the area for deep scratches and gouges. DO-NOT USE ANY BRUSHES; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS AND POSSIBLE INTERNAL TURBO BEARING DAMAGE.NOTE: Fully seat the TC oil supply tube into the TC bore hole flush to 2.5 mm off the mounting surface prior to fastener rundown.
The TC oil supply tube must be installed into the TC fitting along the centerline. The assembly is complete when the TC oil supply tube end bottoms out in the TC brackets bottom on mating surfaces and the M6 fastener has been fully installed. Install the new LHTC oil supply tube, then install and tighten the TC oil supply tube bolts.
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
- Install the LHTC coolant return tube and the bolt.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30°
- Connect LHTC electrical connector.
- Lubricate the new TC fitting and oil filter assembly O-ring seal with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install and tighten the new RHTC fitting and oil filter assembly into the engine block.
Torque: 24 lb.ft (32 Nm)
- Install the new TC gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.
- If a TC cooling tube was separated, then replace the separated TC cooling tube rubber gaskets. After installing the rubber gasket, lubricate with clean engine coolant.
- Install the new TC coolant supply tube and the new TC coolant return tube O-ring seals. Lubricate the new O-ring seal with clean engine coolant.
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NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the TC tube to engine O-ring bores. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.NOTE: Install the coolant tubes with the TC.
Install the RHTC and tighten the retainers in the following 2 stages.
Torque:
Stage 1: Tighten 1-3 in the sequence shown to : 24 lb.ft (32 Nm)
Stage 2: Re-tighten 1 to : 24 lb.ft (32 Nm)
- Install the RHTC coolant supply tube and bolt.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30°
- Lubricate the new RHTC oil return tube O-ring seals with clean engine oil.
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NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger and engine O-ring bores. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.NOTE: Fully seat the TC oil return tube into the turbocharger and engine bore holes flush to 2.5 mm off the mounting surface prior to fastener rundown.
Install the new RHTC oil return tube, then install and tighten the TC oil return tube bolts.
Torque:
Stage 1: 66 lb.ft (89 Nm)
Stage 2: 30°
- Lubricate the new RHTC oil supply tube O-ring seal with clean engine oil.
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NOTE: Use brake cleaner on a lint free rag to remove the O-ring residue out of the TC tube to TC turbocharger O-ring bore. Inspect the area for deep scratches and gouges. DO-NOT USE ANY BRUSHES; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS AND POSSIBLE INTERNAL TURBO BEARING DAMAGE.NOTE: Fully seat the TC oil supply tube into the TC bore hole flush to 2.5 mm off the mounting surface prior to fastener rundown.
The TC oil supply tube must be installed into the TC fitting along the centerline. The assembly is complete when the TC oil supply tube end bottoms out in the TC brackets bottom on mating surfaces and the M6 fastener has been fully installed. Install the new RHTC oil supply tube, then install and tighten the TC oil supply tube bolts.
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30°
- Install the RHTC coolant return tube and the bolt.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30°
- Connect the RHTC electrical connector.
- Install the fuel rail-to-fuel rail high-pressure fuel tube and tighten the flare nuts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30 °
- Install and connect the fuel supply tube. Refer to: Spring Lock Couplings
.
- Install the fuel supply tube spring lock coupling retainers.
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NOTE: Only rotate the crankshaft Clockwise (CW) or damage to the engine may occur.NOTE: The drive lobe for the high-pressure fuel pump must be at BDC for the high-pressure fuel pump installation.
Using the crankshaft pulley bolt, turn the crankshaft until the high-pressure fuel pump drive lobe is at BDC.
- Apply clean engine oil to the high-pressure fuel pump mounting pedestal bore, the drive lobe and the roller tappet. Install the high-pressure fuel pump roller tappet.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Inspect the high-pressure fuel pump mounting plate seal and replace as needed. Lubricate the mounting plate seal with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: Apply clean engine oil to the high-pressure fuel pump O-ring seals.
Install a new high-pressure fuel pump O-ring seal. Lubricate with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
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NOTE: Apply clean engine oil to the high-pressure fuel pump mounting plate O-ring seals.
Inspect the high-pressure fuel pump mounting plate O-ring seals and replace as needed. Lubricate with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)
- Install the high-pressure fuel pump mounting plate on to the high-pressure fuel pump. Install the high-pressure fuel pump bolts.
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- Install the high-pressure fuel pump with the mounting plate and the bolts. Tighten the fuel high-pressure fuel pump bolts in the following 5 stages.
Torque:
Stage 1: Finger tighten all of the bolts : 0 lb.in (0 Nm)
Stage 2: Tighten bolt 1 : 1turn(s)
Stage 3: Tighten bolt 2 : 1turn(s)
Stage 4: Repeat stages 2 and 3, until reaching : 89 lb.in (10 Nm)
Stage 5: Tighten bolts 1 and 2, in sequence an additional : 45°
- Tighten the high-pressure fuel pump mounting plate bolt.
Torque: 89 lb.in (10 Nm)
- Install the high-pressure fuel pump with the mounting plate and the bolts. Tighten the fuel high-pressure fuel pump bolts in the following 5 stages.
- Install and connect the fuel supply tube and the retainers. Refer to: Spring Lock Couplings
.
- Install the fuel supply tube spring lock coupling retainer.
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- Install the high-pressure fuel tube and tighten the flare nuts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 30 °
- Install the new high-pressure fuel tube mounting bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
- Install the high-pressure fuel tube and tighten the flare nuts.
- Connect the high-pressure fuel pump electrical connector.
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NOTE: Use Motorcraft® Orange Antifreeze/Coolant for vehicles built up to 08-July-2018 and Motorcraft® Yellow Antifreeze/Coolant for vehicles built from 09-July-2018. Failure to use the correct coolant can degrade corrosion protection.
Lubricate the O-ring seal with clean engine coolant.
Material: Motorcraft® Orange Prediluted Antifreeze/Coolant / VC-3DIL-B (WSS-M97B44-D2)
Material: Motorcraft® Yellow Prediluted Antifreeze/Coolant / VC-13DL-G (WSS-M97B57-A2)
- Install the water pump outlet connector and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
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NOTE: Use Motorcraft® Orange Antifreeze/Coolant for vehicles built up to 08-July-2018 and Motorcraft® Yellow Antifreeze/Coolant for vehicles built from 09-July-2018. Failure to use the correct coolant can degrade corrosion protection.
Lubricate the O-ring seals with clean engine coolant.
Material: Motorcraft® Orange Prediluted Antifreeze/Coolant / VC-3DIL-B (WSS-M97B44-D2)
Material: Motorcraft® Yellow Prediluted Antifreeze/Coolant / VC-13DL-G (WSS-M97B57-A2)
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- Install the thermostat housing and the bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45°
- Connect the hose and tighten the clamp. Use the General Equipment: Hose Clamp Remover/Installer.
- Install the thermostat housing and the bolts.
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- Install the coolant pump pulley and the bolts.
Torque: 18 lb.ft (24 Nm)
- Install the accessory drive belt tensioner, idler pulley and the bolts.
Torque: 18 lb.ft (25 Nm)
- Install the coolant pump pulley and the bolts.
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- Install the auxiliary coolant pump and the bolts.
Torque: 62 lb.in (7 Nm)
- Connect the auxiliary coolant pump electrical connector.
- Connect the coolant hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer.
- Install the auxiliary coolant pump and the bolts.
- Install the LH engine mount bracket and the bolts.
Torque: 57 lb.ft (77 Nm)
- Install the RH engine mount bracket and the bolts.
Torque: 57 lb.ft (77 Nm)
- Install the RH engine mount and the bolt.
Torque: 258 lb.ft (350 Nm)
- Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)
- Install Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor Crane.
- Remove the engine from the mounting stand.Use Special Service Tool: 303-1246 Engine Spreader Bar., 303-1654 Lift Eyes. Use the General Equipment: Floor CraneUse the General Equipment: Mounting Stand.
- Install the crankshaft sensor ring and the engine-to-transmission spacer plate.
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NOTE: The offset hole may be used in four locations.
Install the flexplate and the bolts.
Torque: 59 lb.ft (80 Nm)