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Section 1507 (Engine - 2.3L - (Hybrid)): Assembly: Engine

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04619129Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04619130Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04619131Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04619132Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft
303-507
G04619133Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04619134Courtesy of FORD MOTOR CO.
 Adapter for 205-126
(205-072-02)
G04619135Courtesy of FORD MOTOR CO.
 Installer, Front Oil Seal
303-096 (T74P-6150-A)
G04619136Courtesy of FORD MOTOR CO.
 Installer, Crankshaft Rear Main Oil Seal
303-328 (T88P-6701-B1)
MATERIALS

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Metal Surface Cleaner
ZC-21		 WSE-M5B392-A
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Motorcraft Silicone Gasket Remover
ZC-30		 -
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Brake Caliper Grease and Dielectric Compound
XG-3-A		 ESE-M1C171-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) WSS-M97B51-A1
High-Temp 4x4 Front Axle and Wheel Bearing Grease
E8TZ-19590-A		 ESA-M1C198-A
Fig 1: Identifying Lower Engine Block Components
G04619137Courtesy of FORD MOTOR CO.
Fig 2: Identifying Front Engine Block Components
G04619138Courtesy of FORD MOTOR CO.
Fig 3: Identifying Cylinder Head Components
G04619139Courtesy of FORD MOTOR CO.
Fig 4: Identifying Intake Manifold Components
G04619140Courtesy of FORD MOTOR CO.
CAUTION:
  1. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
  2. During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
    CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
  2. Remove the engine plug bolt.
    Fig 5: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    3. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
    Fig 6: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Install the block-off plate and bolts.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 7: Locating Block-Off Plate & Bolts
      G04619143Courtesy of FORD MOTOR CO.
    5. NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface cleaner.
  5. Install the oil pump assembly. Tighten the bolts in the sequence shown in the following 2 stages:
    • Stage 1: Tighten to 10 N.m (89 lb-in).
    • Stage 2: Tighten to 20 N.m (15 lb-ft).
      Fig 8: Identifying Tightening Sequence Of Oil Pump Bolts
      G04619144Courtesy of FORD MOTOR CO.
  6. Install a new oil pump pickup tube gasket and the pickup tube.
    • Tighten to 10 N.m (89 lb-in).
      Fig 9: Locating Oil Pump Pickup Tube
      G04619145Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the crankshaft rear main oil seal.
    Fig 10: Installing Crankshaft Rear Main Oil Seal Using Special Tool (303-328)
    G04619146Courtesy of FORD MOTOR CO.
  8. Tighten the crankshaft rear main oil seal bolts in the sequence shown.
    • Tighten to 10 N.m (89 lb-in).
      Fig 11: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
      G04619147Courtesy of FORD MOTOR CO.
    9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool and metal surface cleaner to remove traces of sealant.
  9. Clean and inspect all mating surfaces.
    10. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
  10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
    • Install the oil pan.
    • Install the 2 oil pan bolts finger tight.
      Fig 12: Identifying Rear Oil Pan Bolts
      G03897723Courtesy of FORD MOTOR CO.
  11. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the engine block.
    Fig 13: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block
    G04619149Courtesy of FORD MOTOR CO.
  12. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 14: Identifying Tightening Sequence Of Oil Pan Bolts
      G03897725Courtesy of FORD MOTOR CO.
  13. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 15: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
    14. CAUTION:
    1. Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    2. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  14. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  15. Apply silicone gasket and sealant to the locations shown in Fig 16.
    Fig 16: Identifying Silicone Gasket And Sealant Location
    G03897827Courtesy of FORD MOTOR CO.
  16. Install a new head gasket.
    Fig 17: Locating Head Gasket
    G04619153Courtesy of FORD MOTOR CO.
    17. NOTE:
    1. The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    2. Lubricate the bolts with clean engine oil prior to installation.
  17. Install new cylinder head bolts. Tighten the bolts in the sequence shown in the following 5 stages:
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 15 N.m (11 lb-ft).
    • Stage 3: Tighten to 45 N.m (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
      Fig 18: Identifying Tightening Sequence Of Cylinder Head Bolts
      G04619154Courtesy of FORD MOTOR CO.
    18. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  18. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in the following 3 stages:
    • Stage 1: Tighten 1 turn at a time until tight.
    • Stage 2: Tighten to 7 N.m (62 lb-in).
    • Stage 3: Tighten to 16 N.m (12 lb-ft).
      Fig 19: Identifying Tightening Sequence Of Camshafts & Bearing Caps
      G04619155Courtesy of FORD MOTOR CO.
    19. NOTE: Install a crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
  19. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
    • The crankshaft sprocket flange must be facing away from the engine block.
      Fig 20: Locating Crankshaft Sprocket Flange
      G04619156Courtesy of FORD MOTOR CO.
  20. Install the oil pump chain, sprocket and bolt.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 21: Locating Oil Pump Chain, Sprocket & Bolt
      G04619157Courtesy of FORD MOTOR CO.
  21. Install the oil pump chain guide and the shoulder bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 22: Locating Oil Pump Chain Guide & Shoulder Bolts
      G04619158Courtesy of FORD MOTOR CO.
  22. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    • Tighten to 10 N.m (89 lb-in).
      Fig 23: Locating Oil Pump Chain Tensioner
      G04619159Courtesy of FORD MOTOR CO.
    23. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    Fig 24: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  23. Install the special tool in the slots on the rear of both camshafts.
  24. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 25: Locating Camshaft Sprocket Bolts
    G03897782Courtesy of FORD MOTOR CO.
  25. Install the LH timing chain guide and the bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 26: Identifying Bolts And LH Timing Chain Guide
      G03897780Courtesy of FORD MOTOR CO.
  26. Install the timing chain.
    Fig 27: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  27. Install the RH timing chain guide.
    Fig 28: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 29: Locating Timing Chain Tensioner Plunger
    G04619165Courtesy of FORD MOTOR CO.
  28. Using the edge of a vise, compress the timing chain tensioner plunger.
  29. Using a small pick, push back and hold the ratchet mechanism.
    Fig 30: Pushing Back Ratchet Mechanism
    G04619166Courtesy of FORD MOTOR CO.
  30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 31: Pushing Ratchet Arm Back Into Tensioner Housing
    G04619167Courtesy of FORD MOTOR CO.
  31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 32: Identifying Paper Clip
    G04619168Courtesy of FORD MOTOR CO.
  32. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    • Tighten to 10 N.m (89 lb-in).
      Fig 33: Locating Timing Chain Tensioner & Bolts
      G04619169Courtesy of FORD MOTOR CO.
    33. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  33. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 N.m (53 lb-ft).
      Fig 34: Locating Bolts
      G04619170Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  34. Clean and inspect the mounting surfaces of the engine and the front cover.
    35. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 35: Locating Silicone Gasket
    G03897744Courtesy of FORD MOTOR CO.
  35. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
  36. Install the engine front cover. Tighten the bolts in the sequence shown in Fig 36, to the following specifications:
    • Tighten the 8-mm bolts to 10 N.m (89 lb-in).
    • Tighten the 13-mm bolts to 48 N.m (35 lb-ft).
      Fig 36: Identifying Tightening Sequence Of Engine Front Cover
      G04619172Courtesy of FORD MOTOR CO.
    37. NOTE:
    1. Remove the through-bolt from the special tool.
    2. Lubricate the oil seal with clean engine oil.
    Fig 37: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the crankshaft front oil seal.
    38. CAUTION: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
    Fig 38: Locating Crankshaft Pulley Hole
    G04619174Courtesy of FORD MOTOR CO.
  38. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    39. CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 39: Locating Bolt
    G04619175Courtesy of FORD MOTOR CO.
  39. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
  40. Assemble the special tools using 4 hardened washers in the locations shown.
    Fig 40: Assembling Special Tools (205-072-02 And 205-126)
    G04619176Courtesy of FORD MOTOR CO.
    41. CAUTION:
    1. The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be installed using hand tools only.
    2. Do not reuse the crankshaft pulley bolt.
  41. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 N.m (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
      Fig 41: Installing Crankshaft Pulley Bolt Using Special Tools (205-072-02, 205-126)
      G04619177Courtesy of FORD MOTOR CO.
  42. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 42: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  43. Remove the special tool.
    Fig 43: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  44. Remove the special tool.
    Fig 44: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    45. NOTE: Only turn the engine in the normal direction of rotation.
  45. Turn the crankshaft clockwise 1 and 3/4 turns.
  46. Install the special tool.
    Fig 45: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    47. NOTE: Only turn the engine in the normal direction of rotation.
    Fig 46: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  47. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    48. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  48. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected.
      Fig 47: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
      G03950429Courtesy of FORD MOTOR CO.
  49. Using the special tool, check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected.
      Fig 48: Identifying Special Camshaft Tool (303-465)
      G03898006Courtesy of FORD MOTOR CO.
  50. Remove the special tool.
    Fig 49: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    51. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  51. Install a new crankshaft position (CKP) sensor.
    • Do not tighten the bolts at this time.
      Fig 50: Locating CKP Sensor
      G03898012Courtesy of FORD MOTOR CO.
    52. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
  52. Adjust the CKP sensor with the alignment tool and tighten the bolts.
    • Tighten to 7 N.m (62 lb-in).
      Fig 51: Locating CKP Sensor & Bolts
      G04619187Courtesy of FORD MOTOR CO.
  53. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 52: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  54. Remove the special tool.
    Fig 53: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  55. Install the engine plug bolt.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 54: Locating Engine Plug Bolt
      G04319319Courtesy of FORD MOTOR CO.
    56. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
  56. Clean the valve cover gasket surface with metal surface cleaner.
  57. Apply silicone gasket and sealant to the locations shown in Fig 55.
    Fig 55: Locating Silicone Gasket Applying Area
    G04619191Courtesy of FORD MOTOR CO.
    58. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
  58. Install the valve cover.
    • Tighten the bolts in the sequence shown to 10 N.m (89 lb-in).
      Fig 56: Identifying Tightening Sequence Of Valve Cover Bolts
      G04619192Courtesy of FORD MOTOR CO.
    59. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  59. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
    • Tighten the CHT sensor to 12 N.m (9 lb-ft).
    • Tighten the spark plugs to 12 N.m (9 lb-ft).
      Fig 57: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
      G04619193Courtesy of FORD MOTOR CO.
    60. NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
  60. Install the coil-on-plugs, bolts and the crankcase vent tube.
    • Tighten to 10 N.m (89 lb-in).
      Fig 58: Locating Coil-On-Plugs, Bolts & Crankcase Vent Tube
      G04619194Courtesy of FORD MOTOR CO.
  61. Install the 3 engine cover studs.
    Fig 59: Locating Engine Cover Studs
    G04619195Courtesy of FORD MOTOR CO.
  62. If equipped, install the block heater.
    • Tighten to 21 N.m (15 lb-ft).
      Fig 60: Locating Block Heater
      G04619196Courtesy of FORD MOTOR CO.
  63. Install the coolant hoses.
    Fig 61: Locating Coolant Hoses
    G04619197Courtesy of FORD MOTOR CO.
    64. NOTE: Clean the gasket mating surfaces with metal surface cleaner.
  64. Install the oil filter adapter with a new gasket.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 62: Locating Oil Filter Adapter
      G04619198Courtesy of FORD MOTOR CO.
    65. NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
  65. Install the crankcase vent oil separator and the KS.
    • Tighten the oil separator bolts to 10 N.m (89 lb-in).
    • Tighten the KS to 20 N.m (15 lb-ft).
      Fig 63: Locating Oil Separator Bolts
      G04619199Courtesy of FORD MOTOR CO.
  66. Install the coolant hose.
    Fig 64: Locating Coolant Hose
    G04619200Courtesy of FORD MOTOR CO.
    67. NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket if necessary.
  67. Install the thermostat housing.
    • Tighten to 10 N.m (89 lb-in).
      Fig 65: Locating Thermostat Housing
      G04619201Courtesy of FORD MOTOR CO.
  68. Install the coolant hose.
    Fig 66: Locating Coolant Hose
    G04619202Courtesy of FORD MOTOR CO.
    69. NOTE:
    1. Clean the coolant pump mating surface with metal surface cleaner.
    2. Lubricate the coolant pump O-ring with clean engine coolant.
  69. Install the coolant pump and bolts.
    • Tighten to 10 N.m (89 lb-in).
      Fig 67: Locating Coolant Pump Bolts
      G03897970Courtesy of FORD MOTOR CO.
  70. Install the coolant pump pulley and bolts.
    • Tighten to 20 N.m (15 lb-ft).
      Fig 68: Locating Coolant Pump Pulley Bolts
      G03897969Courtesy of FORD MOTOR CO.
  71. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.
    Fig 69: Locating Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G04619205Courtesy of FORD MOTOR CO.
  72. Connect the radio ignition interference capacitor electrical connector.
    Fig 70: Locating Radio Ignition Interference Capacitor Electrical Connector
    G04619206Courtesy of FORD MOTOR CO.
  73. If equipped, connect the block heater electrical connector.
    Fig 71: Locating Block Heater Electrical Connector
    G04619207Courtesy of FORD MOTOR CO.
  74. Connect the CHT sensor and install the rubber boot.
  75. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 72: Locating Coil-On-Plug & Camshaft Position (CMP) Sensor Electrical Connectors
    G04619208Courtesy of FORD MOTOR CO.
  76. Install the accessory drive belt tensioner.
    • Tighten to 25 N.m (18 lb-ft).
      Fig 73: Locating Accessory Drive Belt Tensioner
      G04619209Courtesy of FORD MOTOR CO.
  77. Attach the engine wiring harness pin-type retainer.
    Fig 74: Locating Engine Wiring Harness Pin-Type Retainer
    G04619210Courtesy of FORD MOTOR CO.
  78. Install the engine wiring harness connector bracket.
    • Tighten to 15 N.m (11 lb-ft).
      Fig 75: Locating Engine Wiring Harness Connector Bracket
      G04619211Courtesy of FORD MOTOR CO.
  79. Connect the CKP sensor electrical connector.
    Fig 76: Locating CKP Sensor Electrical Connector
    G04619212Courtesy of FORD MOTOR CO.
  80. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
    81. NOTE: Special bolts are used for installation. Do not use standard bolts.
  81. Install the flywheel and the bolts. Tighten the bolts in the sequence shown in the following stages:
    • Stage 1: Tighten to 50 N.m (37 lb-ft).
    • Stage 2: Tighten to 80 N.m (59 lb-ft).
    • Stage 3: Tighten to 112 N.m (83 lb-ft).
      Fig 77: Identifying Flexplate Bolts Tightening Sequence
      G03897718Courtesy of FORD MOTOR CO.
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