Section 1153 (Engine -- 4.0L SOHC): Assembly: Engine

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL SPECIFICATIONS

Courtesy of FORD MOTOR CO.	Tensioner, Timing Chain 303-571 (T97T-6K254-A)
Courtesy of FORD MOTOR CO.	Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B)
Courtesy of FORD MOTOR CO.	Adapter for 303-564 303-578 (T97T-6256-A)
Courtesy of FORD MOTOR CO.	Holding Tool, Camshaft 303-577 (T97T-6256-C)
Courtesy of FORD MOTOR CO.	Adapter for 303-577 303-576 (T97T-6256-D)
Courtesy of FORD MOTOR CO.	Strap Wrench 303-D055 (85L-6000-A) or equivalent
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
Courtesy of FORD MOTOR CO.	Compressor, Piston Ring 303-D032 (D81L-6002-C)
Courtesy of FORD MOTOR CO.	Compressor, Valve Spring 303-581 (T97T-6565-A)
Courtesy of FORD MOTOR CO.	Crankshaft Socket 303-674
Courtesy of FORD MOTOR CO.	Lifting Eyes 303-050
Courtesy of FORD MOTOR CO.	Service Set, Crankshaft Rear Oil Seal 303-S524 (T95T-6701-AR)
Courtesy of FORD MOTOR CO.	Aligner, Front Cover 303-093 (T74P-6019-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A)

MATERIAL SPECIFICATIONS

Item	Specification
SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP or equivalent	WSS-M2C929-A
Motorcraft Silicone Gasket Remover ZC-30	-
Motorcraft Metal Surface Prep ZC-31	-
Silicone Gasket and Sealant TA-30 or equivalent	WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A or equivalent	ESE-M1C171-A

Upper End-4.0L SOHC Engine

Fig 1: Identifying Engine Components - Upper End 4.0L SOHC Engine

Courtesy of FORD MOTOR CO.

Lower End-4.0L SOHC Engine

Fig 2: Identifying Engine Components - Lower End 4.0L SOHC Engine

Courtesy of FORD MOTOR CO.

CAUTION: If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.

NOTE: During engine assembly it may be necessary to check the bearing clearances and crankshaft end play. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

NOTE: Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

All engines

Install the crankshaft main bearings and the thrust bearing.
- Lubricate the crankshaft main bearings with clean engine oil.
Install the lower main bearings in the bearing caps.

Fig 3: Installing Lower Main Bearings In Bearing Caps
Courtesy of FORD MOTOR CO.

NOTE: The crankshaft main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

Fig 4: Installing Crankshaft

Courtesy of FORD MOTOR CO.

Install the crankshaft.

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

Fig 5: Applying Silicone Gasket And Sealant To Rear Main Bearing Cap To Cylinder Block Parting Line

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
Install the main bearing caps in the order in which they were removed.

Fig 6: Installing Main Bearing Caps
Courtesy of FORD MOTOR CO.
Tighten the bolts.
- Tighten to 97 Nm (72 lb-ft).
  
  Fig 7: Tightening Bolts
  Courtesy of FORD MOTOR CO.
Check the piston to cylinder bore and ring clearance. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

NOTE: Lubricate the piston rings with clean engine oil.

Install the piston rings.
Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

Fig 8: Installing Piston Rings
Courtesy of FORD MOTOR CO.
Install the connecting rod bearings.

Fig 9: Installing Connecting Rod Bearings
Courtesy of FORD MOTOR CO.
Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.

Fig 10: Installing Rubber Hose Pieces On Connecting Rod Bolts
Courtesy of FORD MOTOR CO.

NOTE: Position the piston with the indentation arrow toward the front of the cylinder block.

Using the special tool, install the pistons.
- Rotate the crankshaft as necessary.
  
  Fig 11: Installing Pistons Using Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.

Check the clearance of each connecting rod bearing. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
Rotate the crankshaft until the piston is at the bottom of its stroke.

NOTE: For cylinders 1, 2 and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5 and 6, remove the opposite nut first.

Fig 12: Loosening First Nut

Courtesy of FORD MOTOR CO.

Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
Tap on the nut until the bolt can be removed by hand.

Fig 13: Taping On Nut
Courtesy of FORD MOTOR CO.
Repeat the previous 2 steps for the opposite bolt.
Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.

Fig 14: Installing Bolts
Courtesy of FORD MOTOR CO.
Install the connecting rod cap in the original position.
Install and tighten the connecting rod nuts finger-tight.

Fig 15: Tightening Connecting Rod Nuts
Courtesy of FORD MOTOR CO.
Tighten the connecting rod nuts simultaneously in 2 stages:
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Repeat the previous 4 steps for the remaining connecting rods.
Rotate crankshaft until the No. 1 piston is at top dead center.
Install the balance shaft.
1. Install the balance shaft assembly.
2. Install the bolts.
  - Tighten to 27 Nm (20 lb-ft).
    
    Fig 16: Installing Balance Shaft
    Courtesy of FORD MOTOR CO.

NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position.

Align the timing marks.
- Install a 4-mm (0.16-in) pin to hold the shaft in place.
  
  Fig 17: Aligning Timing Marks
  Courtesy of FORD MOTOR CO.
Install the balance shaft chain and crankshaft sprocket.

Fig 18: Installing Balance Shaft Chain And Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the balance shaft tensioner.
1. Install the balance shaft tensioner.
2. Install the bolts.
3. Position the balance shaft chain guide and install the 2 bolts.
  - Remove the pins from the tensioner and the sprocket.
  - Install the crankshaft key.
    
    Fig 19: Installing Balance Shaft Tensioner
    Courtesy of FORD MOTOR CO.
Install the oil pump intermediate shaft, the oil pump and the bolt.
- Tighten to 19 Nm (14 lb-ft).
  
  Fig 20: Installing Oil Pump Intermediate Shaft, Oil Pump And Bolt
  Courtesy of FORD MOTOR CO.
Install the jackshaft.

Fig 21: Installing Jackshaft
Courtesy of FORD MOTOR CO.
Install the jackshaft thrust plate and bolts.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 22: Installing Jackshaft Thrust Plate And Bolts
  Courtesy of FORD MOTOR CO.
Install the front cassette and bolt.
- Tighten to 19 Nm (14 lb-ft).
  
  Fig 23: Installing Front Cassette And Bolt
  Courtesy of FORD MOTOR CO.
Position the jackshaft and crankshaft sprockets and the chain.

Fig 24: Positioning Jackshaft And Crankshaft Sprockets And Chain
Courtesy of FORD MOTOR CO.
Install the chain guide and the bolts.
- Tighten to 19 Nm (14 lb-ft).
  
  Fig 25: Installing Chain Guide And Bolts
  Courtesy of FORD MOTOR CO.
Install the chain tensioner and the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 26: Installing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, hold the crankshaft.

Fig 27: Holding Crankshaft Using Special Tool
Courtesy of FORD MOTOR CO.
Install the jackshaft front bolt and tighten in 2 stages.
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 28: Locating Jackshaft Sprocket Bolt
  Courtesy of FORD MOTOR CO.
Install the oil pump drive and the bolt.
- Tighten to 19 Nm (14 lb-in).
  
  Fig 29: Installing Oil Pump Drive And Bolt
  Courtesy of FORD MOTOR CO.
Install the RH cassette and sprocket to the jackshaft.
- Install, but do not tighten the bolt at this time.
  
  Fig 30: Installing RH Cassette And Sprocket To Jackshaft
  Courtesy of FORD MOTOR CO.
Install the RH cassette bolt.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 31: Installing RH Cassette Bolt
  Courtesy of FORD MOTOR CO.
Using the special tool, hold the crankshaft.

Fig 32: Holding Crankshaft Using Special Tool
Courtesy of FORD MOTOR CO.
Tighten the rear jackshaft bolt in 2 stages.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 33: Tightening Rear Jackshaft Bolt
  Courtesy of FORD MOTOR CO.
Install the rear jackshaft plug.

Fig 34: Installing Rear Jackshaft Plug
Courtesy of FORD MOTOR CO.
Position the front cover gasket, the front cover and loosely install the bolts.

Fig 35: Positioning Front Cover Gasket
Courtesy of FORD MOTOR CO.
Install the special tool and tighten the front cover bolts.
- Tighten to 19 Nm (14 lb-ft).
  
  Fig 36: Tightening Front Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the seal lip with clean engine oil.

Fig 37: Installing Crankshaft Front Oil Seal Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tools, install the crankshaft front oil seal.

Fig 38: Applying Silicone Gasket And Sealant To Front Cover

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the front cover in 4 places.

Apply silicone gasket and sealant to the rear main bearing cap as shown in Fig 39.
- Position the cylinder block cradle gasket.
  
  Fig 39: Applying Silicone Gasket And Sealant To Rear Main Bearing Cap
  Courtesy of FORD MOTOR CO.

CAUTION: The cylinder block cradle inserts must be loosened completely or damage to the cylinder block cradle or oil leaks can result.

Fig 40: Loosening Cylinder Block Cradle Inserts

Courtesy of FORD MOTOR CO.

Loosen the cylinder block cradle inserts.
Position the cylinder block cradle and gasket assembly.

Fig 41: Identifying Cylinder Block Cradle And Gasket Assembly
Courtesy of FORD MOTOR CO.
Install and finger-tighten the 20 bolts and 2 nuts.

Fig 42: Locating Outer Bolts
Courtesy of FORD MOTOR CO.
Install and finger-tighten the Torx bolts.

Fig 43: Tightening Torx Bolts
Courtesy of FORD MOTOR CO.

NOTE: The cylinder block cradle to the cylinder block alignment must be within a maximum mismatch of 0.25-mm (0.01-in) cylinder block cradle underflush or 0.05-mm (0.00196-in) cylinder block cradle protrusion.

Fig 44: Aligning Transmission Face Of Cylinder Block Cradle With Rear Face Of Cylinder Block

Courtesy of FORD MOTOR CO.

Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
Tighten the 20 bolts and the 2 nuts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 45: Locating Outer Bolts
  Courtesy of FORD MOTOR CO.
Tighten the Torx bolts.
- Tighten to 8 Nm (81 lb-in).
  
  Fig 46: Tightening Torx Bolts
  Courtesy of FORD MOTOR CO.
Tighten the inserts.
- Tighten to 3 Nm (27 lb-in).
  
  Fig 47: Tightening Inserts
  Courtesy of FORD MOTOR CO.
Install new seals on the 2 silver bolts and position them in the cylinder block cradle.

Fig 48: Installing Seals On Silver Bolts
Courtesy of FORD MOTOR CO.
Position the 6 remaining bolts.

Fig 49: Positioning Remaining Bolts
Courtesy of FORD MOTOR CO.
Tighten the cylinder block cradle inner bolts in the sequence shown 2 stages.
- Stage 1: Tighten to 15 Nm (11 lb-ft).
- Stage 2: Tighten to 34 Nm (25 lb-ft).
  
  Fig 50: Tightening Cylinder Block Cradle Inner Bolts In Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Assemblies that measured out of specification must have the entire assembly procedure repeated.

Fig 51: Measuring Step Between Rear Face Of Cylinder Block And Transmission Face Of Cylinder Block Cradle

Courtesy of FORD MOTOR CO.

Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle.
Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the cylinder block cradle.

Fig 52: Installing Shims On Or Both Sides Of Cylinder Block Cradle
Courtesy of FORD MOTOR CO.
Install the oil pump screen cover and tube and the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 53: Installing Oil Pump Screen Cover And Tube And Bolt
  Courtesy of FORD MOTOR CO.
Install the gasket, the oil pan and the bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 54: Installing Gasket, Oil Pan And Bolts
  Courtesy of FORD MOTOR CO.
Install the oil filter adapter and the bolt.
- Tighten to 57 Nm (42 lb-in).
  
  Fig 55: Installing Oil Filter Adapter And Bolt
  Courtesy of FORD MOTOR CO.
Install the coolant pump and the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 56: Installing Coolant Pump And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 57: Installing Cylinder Head Gaskets

Courtesy of FORD MOTOR CO.

Install the cylinder head gaskets.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages.
- Stage 1: Tighten the bolts to 12 Nm (9 lb-ft).
- Stage 2: Tighten the bolts to 25 Nm (18 lb-ft).
  
  Fig 58: Identifying Tightening Sequence Of Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
  
  Fig 59: Installing 8-mm Bolts
  Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
  
  Fig 60: Tightening Bolts In Sequence
  Courtesy of FORD MOTOR CO.

NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 12 Nm (9 lb-ft).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
  
  Fig 61: Installing 12-mm Bolts
  Courtesy of FORD MOTOR CO.
Install 2 new 8-mm bolts.
- Tighten to 32 Nm (24 lb-ft).
  
  Fig 62: Installing 8-mm Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 8 12-mm bolts in the sequence shown in 2 stages.
- Stage 1: Rotate 90 degrees.
- Stage 2: Rotate an additional 90 degrees.
  
  Fig 63: Identifying Tightening Sequence Of 12-mm Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft pulley.

Fig 64: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: A new bolt must be used each time it is removed.

Using the special tool, tighten the bolt in 2 stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Rotate an additional 90 degrees.
  
  Fig 65: Tightening Bolt In Stages Using Special Tool
  Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and the bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 66: Installing Coolant Pump Pulley And Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Fig 67: Identifying RH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Loosely install the RH camshaft sprocket bolt.
Install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 68: Installing Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.

Fig 69: Identifying LH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Loosely install the LH camshaft sprocket bolt.
Install the bolt.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 70: Identifying LH Cassette Upper Bolt
  Courtesy of FORD MOTOR CO.
Turn the crankshaft one revolution clockwise.

CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.

NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).

Fig 71: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool.

NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Fig 72: Installing Special Tools On Front Of RH Cylinder Head

Courtesy of FORD MOTOR CO.

Install the special tools on the front of the RH cylinder head.

NOTE: Leave the top 2 special tool clamp bolts loose.

Fig 73: Identifying Special Holding Tool

Courtesy of FORD MOTOR CO.

Install the special tools on the rear of the RH cylinder head.
Install the special tool.

Fig 74: Installing Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.

Tighten the bolts.
1. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
  
  Fig 75: Tightening Camshaft Bolt
  Courtesy of FORD MOTOR CO.
Remove the special tool and install the RH camshaft tensioner.
- Tighten to 44 Nm (32 lb-ft).
  
  Fig 76: Installing RH Camshaft Tensioner
  Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the special tool top 2 clamp bolts. Camshaft sprocket must rotate freely.

Fig 77: Identifying Special Holding Tool

Courtesy of FORD MOTOR CO.

Install the special tools on the front of the LH cylinder head.

NOTE: Camshaft timing slots are off-center.

NOTE: Position the camshaft timing slots below centerline of camshaft to correctly fit the special tools.

Fig 78: Installing Special Tools On Rear Of LH Cylinder Head

Courtesy of FORD MOTOR CO.

Install the special tools on the rear of the LH cylinder head.
Install the special tool.

Fig 79: Installing Special Tool
Courtesy of FORD MOTOR CO.
Tighten the bolts.
1. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in).
2. Tighten the camshaft bolt to 85 Nm (63 lb-ft).
  
  Fig 80: Tightening Camshaft Bolt
  Courtesy of FORD MOTOR CO.
Install the LH camshaft tensioner.
- Tighten to 44 Nm (32 lb-ft).
  
  Fig 81: Identifying LH Camshaft Tensioner
  Courtesy of FORD MOTOR CO.
Rotate the crankshaft until the cam lobe is in the UP position.

Fig 82: Identifying Crankshaft Cam Lobe
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the parts with clean engine oil.

Fig 83: Installing Roller Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the roller followers in their original positions.
Install a new gasket and the RH exhaust manifold and nuts.

Fig 84: Installing RH Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Install a new gasket and the LH exhaust manifold and nuts.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 85: Installing LH Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.

NOTE: Prior to installation, use metal surface prep to clean mating surfaces. Follow the directions on the packaging

Install the knock sensor (KS) and the bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 86: Installing Knock Sensor And Bolt
  Courtesy of FORD MOTOR CO.
Install the oil level indicator tube and bolt.

Fig 87: Locating Bolt And Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Position the thermostat housing and bypass hose on the coolant pump.
1. Install the bolts.
  - Tighten to 11 Nm (8 lb-ft).
2. Position the bypass hose clamp.
  
  Fig 88: Positioning Bypass Hose Clamp
  Courtesy of FORD MOTOR CO.

NOTE: RH valve cover shown, LH similar.

Install the valve covers and tighten the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 89: Installing Valve Covers
  Courtesy of FORD MOTOR CO.

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

Fig 90: Locating O-Ring Seals

Courtesy of FORD MOTOR CO.

Install new O-ring seals on each of the fuel injectors.

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

Fig 91: Installing Fuel Injectors

Courtesy of FORD MOTOR CO.

Install the fuel injectors.
Install the fuel rail and the bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 92: Installing Fuel Rail And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the LH and RH insulator brackets and the bolts.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 93: Installing LH And RH Insulator Brackets And Bolts
  Courtesy of FORD MOTOR CO.
Install the oil pressure switch.
- Tighten to 14 Nm (10 lb-ft).
  
  Fig 94: Installing Oil Pressure Switch
  Courtesy of FORD MOTOR CO.
Install the battery cable and the bolt and connect the oil pressure switch electrical connector.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 95: Installing Battery Cable And Bolt
  Courtesy of FORD MOTOR CO.
Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.

Fig 96: Connecting Fuel Pressure And Temperature Sensor Vacuum Hose Fittings
Courtesy of FORD MOTOR CO.
Position the engine wiring harness on the engine.

Fig 97: Positioning Engine Wiring Harness On Engine
Courtesy of FORD MOTOR CO.
Position the engine wiring harness retainer and install the bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 98: Positioning Engine Wiring Harness Retainer
  Courtesy of FORD MOTOR CO.
Connect the crankshaft position (CKP) sensor electrical connectors and new wiring anchors.

Fig 99: Connecting Crankshaft Position Sensor Electrical Connectors And Wiring Anchors
Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 100: Connecting Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the 6 fuel injector electrical connectors.
Install the gaskets, intake manifold and the bolts.
- Tighten to 11 Nm (8 lb-ft).
  
  Fig 101: Installing Gaskets, Intake Manifold And Bolts
  Courtesy of FORD MOTOR CO.
Connect the exhaust gas recirculation (EGR) system module vacuum hose and electrical connector.
- Attach the wiring harness pin-type retainer.
  
  Fig 102: Attaching Wiring Harness Pin-Type Retainer
  Courtesy of FORD MOTOR CO.
Connect the electronic throttle body and throttle position (TP) sensor electrical connectors.

Fig 103: Connecting Electronic Throttle Body And Throttle Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the wiring harness pin-type retainer and connect the knock sensor electrical connector.

Fig 104: Connecting Knock Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Position the fuel tube.

Fig 105: Positioning Fuel Tube
Courtesy of FORD MOTOR CO.

Engines equipped with an oil cooler

Install the oil cooler and hoses.
- Tighten to 57 Nm (42 lb-ft).
  
  Fig 106: Installing Oil Cooler And Hoses
  Courtesy of FORD MOTOR CO.
Position the oil cooler hose brackets and install the bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 107: Installing Bolts
  Courtesy of FORD MOTOR CO.

All engines

Position the ignition coil and bracket assembly and install the bolts.
- Tighten to 10 Nm (89 lb-ft).
  
  Fig 108: Positioning Ignition Coil And Bracket Assembly
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.

NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.

Fig 109: Connecting Spark Plug Wires

Courtesy of FORD MOTOR CO.

Connect the spark plug wires.
Connect the following electrical connectors:
- Camshaft position (CMP) sensor.
- Ignition coil.
- Engine coolant temperature (ECT) sensor.
- Ignition radio interference capacitor.
- Fuel pressure and temperature sensor.
  
  Fig 110: Connecting Electrical Connectors
  Courtesy of FORD MOTOR CO.
Install the generator mounting bracket.
1. Install the generator mounting bracket bolts.
  - Tighten to 42 Nm (31 lb-ft).
2. Install the drive belt tensioner and bolt.
  - Tighten to 47 Nm (35 lb-ft).
    
    Fig 111: Installing Drive Belt Tensioner And Bolt
    Courtesy of FORD MOTOR CO.
Connect the generator electrical connections and the wire harness retainer.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 112: Connecting Generator Electrical Connections And Wire Harness Retainer
  Courtesy of FORD MOTOR CO.
Install the accessory bracket and the bolts.
- Tighten to 42 Nm (31 lb-ft).
  
  Fig 113: Installing Accessory Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connector and wire harness retainer.

Fig 114: Connecting A/C Compressor Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
Install the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 115: Installing Bolts
  Courtesy of FORD MOTOR CO.
Install the A/C hose.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 116: Installing A/C Hose
  Courtesy of FORD MOTOR CO.
Install the right side lifting bracket.
- Tighten to 37 Nm (27 lb-ft).
  
  Fig 117: Installing Right Side Lifting Bracket
  Courtesy of FORD MOTOR CO.
Install the left side lifting bracket.

Fig 118: Installing Left Side Lifting Bracket
Courtesy of FORD MOTOR CO.
Using the special tool and a floor crane, remove the engine from the engine stand.

Fig 119: Removing Engine From Engine Stand Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Be sure that the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use an extra-fine emery cloth or an extra-fine steel wool with metal surface cleaner.

Fig 120: Installing Crankshaft Rear Oil Seal On Special Tool

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft rear oil seal with engine oil and install it on the special tool.
Install the special tools.

Fig 121: Installing Special Tools
Courtesy of FORD MOTOR CO.
Position the crankshaft rear seal and the special tool.

Fig 122: Positioning Crankshaft Rear Seal And Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft rear oil seal.

Fig 123: Installing Crankshaft Rear Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Install the spacer plate.

NOTE: Special bolts are used for flexplate installation. Do not use standard bolts.

Install the flexplate.
- Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 13 Nm (10 lb-ft).
- Stage 2: Tighten to 71 Nm (52 lb-ft).
  
  Fig 124: Installing Flexplate
  Courtesy of FORD MOTOR CO.