Section 973 (Engine - 5.4L (3V) - F150 Pickup): Assembly: Engine

	Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
	Installer, Connecting Rod 303-442 (T93P-6136-A)
	Compressor, Valve Spring 303-1039
	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
	Installer, Crankshaft Front Seal 303-635
	Installer, Front Cover Seal 303-335 (T88T-6701-A)
	Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
	Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH)
	Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH)
	Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH)
	Holding Tool, Crankshaft 303-448 (T93P-6303-A)
	Alignment Pins, Cylinder Head 303-1040 (SR-015486)
	Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
	Locking Tool, Camshaft Phaser Sprocket 303-1046

Engine - Upper End 

Fig 1: Exploded View Of Engine - Upper End

Courtesy of FORD MOTOR CO.

Fig 2: Item Description Of Engine - Upper End (Items 1-69)

Courtesy of FORD MOTOR CO.

Engine - Front End 

Fig 3: Exploded View Of Engine - Front End

Courtesy of FORD MOTOR CO.

Engine - Lower End 

Fig 4: Exploded View Of Engine - Lower End

Courtesy of FORD MOTOR CO.

Fig 5: Item Description Of Engine - Lower End (Items 1-49)

Courtesy of FORD MOTOR CO.

1. Record the main bearing code found on the front of the engine block.
   Fig 6: Identifying Main Bearing Code Label Location (Engine Block)

   Courtesy of FORD MOTOR CO.
2. Record the main bearing code found on the back of the crankshaft.
   Fig 7: Identifying Main Bearing Code - Found On Back Of Crankshaft

   Courtesy of FORD MOTOR CO.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
   • 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 for the number one crankshaft main bearing.
   • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is a "2."
   • Repeat this process for the remaining 4 main bearings.
   Fig 8: Bearing Select Fit Chart (Standard Bearings)

   Courtesy of FORD MOTOR CO.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
   Fig 9: Bearing Select Fit Chart (Oversize Bearings)

   Courtesy of FORD MOTOR CO.
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.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper thrust washers until the crankshaft is installed. Refer to the following 2 steps.
Fig 10: Installing Crankshaft Onto Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
6. Install the crankshaft onto the upper crankshaft main bearings.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
Fig 11: Installing Rear Crankshaft Upper Thrust Washer At Back Of No. 5 Main Boss
Courtesy of FORD MOTOR CO.
7. Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).
Fig 12: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss
Courtesy of FORD MOTOR CO.
8. Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft surface).
Fig 13: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap, With Oil Grooves Facing The Crankshaft Surface
Courtesy of FORD MOTOR CO.
9. Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the dowel pins so the flat sides face the crankshaft.
    Fig 14: Installing Dowel Pins So Flat Sides Face Crankshaft

    Courtesy of FORD MOTOR CO.
12. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
    • Tighten to 40 Nm (30 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 15: Identifying Tightening Sequence Of Vertical Main Bearing Cap Fasteners

    Courtesy of FORD MOTOR CO.
13. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 30 Nm (22 lb-ft).
    • Tighten an additional 90 degrees.
    Fig 16: Identifying Tightening Sequence Of Side Bolts

    Courtesy of FORD MOTOR CO.
14. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
15. Assemble the 8 pistons. For additional information, refer to PISTON .
16. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
    Fig 17: Identifying Ring Gaps (Oil Spacer-A, Oil Ring-B, Compression Ring-C) Are Correctly Spaced Around Circumference Of Piston

    Courtesy of FORD MOTOR CO.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only 1 connecting rod, rod bearing and piston is shown.
Fig 18: Using Special Tools To Install Connecting Rod With Upper Connecting Rod Bearing In Place
Courtesy of FORD MOTOR CO.
17. Use the special tools to install the connecting rod with the upper connecting rod bearing in place.
    • Lubricate the piston and ring with clean engine oil
    • Lubricate the rod bearings with clean engine oil.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 19: Seating Connecting Rod On Crankshaft Journal Using Special Tools
Courtesy of FORD MOTOR CO.
18. Once the connecting rod is seated on the crankshaft journal, remove the special tools.
CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.
19. Position the lower bearing and connecting rod, and install the new bolts loosely.
NOTE: Main bearing caps are removed for clarity.
Fig 20: Identifying Tightening Sequence Of Lower Bearing And Connecting Rod Bolts
Courtesy of FORD MOTOR CO.
20. Tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 43 Nm (32 lb-ft).
    • Stage 2: Tighten an additional 105 degrees.
21. Position the oil pump and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 21: Installing Oil Pump Bolts

    Courtesy of FORD MOTOR CO.
22. Install the oil pump screen and pickup tube spacer.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 22: Installing Oil Pump Screen And Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation.
Fig 23: Positioning Oil Pump Screen, Pickup Tube And Installing Bolts
Courtesy of FORD MOTOR CO.
23. Position the oil pump screen and pickup tube and install the bolts.
    • Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
    • Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
24. Position the crankshaft with the special tool, then remove the tool.
    Fig 24: Positioning Crankshaft With Special Tool

    Courtesy of FORD MOTOR CO.
CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Fig 25: Using Special Tools To Position Cylinder Head Gaskets And Cylinder Heads Over Dowels And Installing Cylinder Head Bolts Loosely
Courtesy of FORD MOTOR CO.
25. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
26. Tighten the bolts in 3 stages, in the sequence shown.

    RH shown, LH similar. 

    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
    Fig 26: Identifying Tightening Sequence Of Bolts

    Courtesy of FORD MOTOR CO.
27. Remove the special tool from the LH cylinder head.
    Fig 27: Removing Special Tool From LH Cylinder Head

    Courtesy of FORD MOTOR CO.
28. Remove the special tool from the RH cylinder head.
    Fig 28: Removing Special Tool From RH Cylinder Head

    Courtesy of FORD MOTOR CO.
29. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
    • Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
    Fig 29: Installing Hydraulic Lash Adjusters Into RH And LH Cylinder Heads

    Courtesy of FORD MOTOR CO.
30. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
NOTE: LH shown, RH similar.
Fig 30: Installing LH And RH Camshaft Bearing Caps In Their Original Locations
Courtesy of FORD MOTOR CO.
31. Install the LH and RH camshaft bearing caps in their original locations.
    • Lubricate the camshaft bearing caps with clean engine oil.
    • Position the front camshaft bearing cap.
    • Position the remaining camshaft bearing caps.
    • Install the bolts loosely.
    • Tighten to 10 Nm (89 lb-in) in the sequence shown.
CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE: LH shown, RH similar.
Fig 31: Installing VCT Phaser Sprockets And New VCT Phaser Bolts Finger Tight
Courtesy of FORD MOTOR CO.
32. Install the VCT phaser sprockets and new VCT phaser bolts finger tight.
CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
NOTE: LH shown, RH similar.
33. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 N.m (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 32: Identifying Special Sprocket Phase Tool
Courtesy of FORD MOTOR CO.
CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Failure to follow these instructions may result in engine damage.
34. Compress the tensioner plunger, using a vise.
Fig 33: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
35. Install a retaining clip on the tensioner to hold the plunger in during installation.
Fig 34: Identifying Retaining Clip on Tensioner
Courtesy of FORD MOTOR CO.
36. Remove the tensioner from the vise.
37. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
Fig 35: Locating Timing Chain Marks
Courtesy of FORD MOTOR CO.
38. Install the crankshaft sprocket, making sure the flange faces forward.
Fig 36: Identifying Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
39. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 N.m (89 lb-in).
Fig 37: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.
40. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
Fig 38: Aligning Crankshaft Sprocket Timing Mark And LH Timing Chain Link
Courtesy of FORD MOTOR CO.
NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
41. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.
Fig 39: Identifying Copper Links Of Timing Chain On VCT Phaser Sprocket
Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
42. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 40: Identifying LH Timing Chain Tensioner & Tensioner Arm
Courtesy of FORD MOTOR CO.
43. Remove the retaining clip from the LH timing chain tensioner.
Fig 41: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
44. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
Fig 42: Aligning Crankshaft Sprocket Timing Mark And RH Timing Chain Link
Courtesy of FORD MOTOR CO.
NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
45. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
Fig 43: Positioning RH Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
46. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 N.m (18 lb-ft).
Fig 44: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
Courtesy of FORD MOTOR CO.
47. Remove the retaining clip from the RH timing chain tensioner.
Fig 45: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
48. As a post-check, verify correct alignment of all timing marks.
Fig 46: Locating Timing Marks - Post Check
Courtesy of FORD MOTOR CO.
49. Install the crankshaft sensor ring on the crankshaft.
Fig 47: Locating Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage.
50. Using the special tool, install all of the camshaft roller followers.
    • Lubricate the camshaft roller followers with clean engine oil prior to installation.
Fig 48: Compressing Spring Using Special Tool (303-1039)
Courtesy of FORD MOTOR CO.
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 to remove all traces of old sealant.
NOTE: If the engine front cover is 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. 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.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
51. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
Fig 49: Applying Bead Of Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
52. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
    Fig 50: Positioning Engine Front Cover Onto Dowels

    Courtesy of FORD MOTOR CO.
53. Tighten the engine front cover fasteners in the sequence shown in 2 stages.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Fig 51: Tightening Engine Front Cover Fasteners In Sequence

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Fig 52: Installing LH Camshaft Position (CMP) Sensor And Bolt
Courtesy of FORD MOTOR CO.
54. Install the LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
Fig 53: Installing RH CMP Sensor And Bolt
Courtesy of FORD MOTOR CO.
55. Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
Fig 54: Positioning Coolant Pump
Courtesy of FORD MOTOR CO.
56. Position the coolant pump and install the bolts loosely.
    • Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.
57. Tighten the 4 coolant pump bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 55: Tightening Coolant Pump Bolts

    Courtesy of FORD MOTOR CO.
58. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 56: Installing Crankshaft Front Seal

    Courtesy of FORD MOTOR CO.
59. Using the special tools, install a new crankshaft seal into the engine front cover.
    Fig 57: Using Special Tools To Install New Crankshaft Seal Into Engine Front Cover

    Courtesy of FORD MOTOR CO.
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. 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.
Fig 58: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
60. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
61. Use the special tool to install the crankshaft pulley.
    Fig 59: Using Special Tool To Install Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
62. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 60: Tightening New Crankshaft Pulley Bolts

    Courtesy of FORD MOTOR CO.
63. Position the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 61: Positioning Crankshaft Position (CKP) Sensor And Bolt

    Courtesy of FORD MOTOR CO.
64. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 62: Identifying Accessory Drive Belt Tensioner Bolts

    Courtesy of FORD MOTOR CO.
65. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 63: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts

    Courtesy of FORD MOTOR CO.
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 to remove all traces of old sealant.
NOTE: Clean and inspect the mating surfaces, and install new gaskets.
Fig 64: Positioning Oil Filter Adapter
Courtesy of FORD MOTOR CO.
66. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
67. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 65: Identifying Bolt Tightening/Loosening Sequence Of LH Exhaust Manifold

    Courtesy of FORD MOTOR CO.
68. Installing LH engine support insulator and 3 bolts.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 66: Installing LH Engine Support Insulator Bolts

    Courtesy of FORD MOTOR CO.
69. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 67: Positioning New Gasket, Rh Exhaust Manifold And Tightening Nuts In Sequence

    Courtesy of FORD MOTOR CO.
70. Install the RH engine support insulator and the 3 bolts.
    • Tighten to 63 Nm (46 lb-ft).
    Fig 68: Installing RH Engine Support Insulator And 3 Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
71. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. 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.
Fig 69: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
72. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Fig 70: Identifying Tighten Sequence Of LH Valve Cover Bolts
Courtesy of FORD MOTOR CO.
73. Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
74. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. 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.
Fig 71: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
75. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Fig 72: Identifying Tighten Sequence Of RH Valve Cover Bolts
Courtesy of FORD MOTOR CO.
76. Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
77. Install the oil level indicator tube and the bolt.
    • Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
    • Tighten to 10 Nm (89 lb-in).
    Fig 73: Installing Oil Level Indicator Tube And Bolt

    Courtesy of FORD MOTOR CO.
NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation.
Fig 74: Sliding Coolant Tube Forward With New O-Ring Seals Into Cylinder Block
Courtesy of FORD MOTOR CO.
78. Slide the coolant tube forward with the new O-ring seals into the cylinder block.
79. Install the coolant tube stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    Fig 75: Installing Coolant Tube Stud Bolt

    Courtesy of FORD MOTOR CO.
80. Install the 2 knock sensors (KS) and the bolts.
    • Tighten to 20 Nm (15 lb-ft).
    Fig 76: Installing Knock Sensors (KS) And Bolts

    Courtesy of FORD MOTOR CO.
81. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
82. Connect the CKP sensor electrical connector.
    Fig 77: Connecting CKP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
Fig 78: Installing Ignition Coils And Bolts
Courtesy of FORD MOTOR CO.
83. Install the 8 ignition coils and the 8 bolts.
    • Tighten to 6 Nm (53 lb-in).
84. Connect the 4 LH ignition coil electrical connectors.
    Fig 79: Connecting LH Ignition Coil Electrical Connectors

    Courtesy of FORD MOTOR CO.
85. Install the LH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 80: Installing LH Radio Ignition Interference Capacitor And Stud Bolt

    Courtesy of FORD MOTOR CO.
86. Connect the LH CMP sensor electrical connector.
    Fig 81: Connecting LH CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
87. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 82: Connecting Engine Oil Pressure (EOP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
88. Connect the LH VCT solenoid electrical connector.
    Fig 83: Connecting LH VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
89. Connect the 2 engine wiring harness retainers to the LH valve cover studs.
    Fig 84: Connecting Engine Wiring Harness Retainers To LH Valve Cover Studs

    Courtesy of FORD MOTOR CO.
90. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 85: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
91. Connect the 4 RH ignition coil electrical connectors.
    Fig 86: Connecting RH Ignition Coil Electrical Connectors

    Courtesy of FORD MOTOR CO.
92. Connect the electrical connector retainer to the coolant tube.
    Fig 87: Connecting Electrical Connector Retainer To Coolant Tube

    Courtesy of FORD MOTOR CO.
93. Connect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 88: Connecting Engine Wiring Harness Retainers From RH Valve Cover Studs

    Courtesy of FORD MOTOR CO.
94. Connect the RH VCT solenoid electrical connector.
    Fig 89: Connecting RH VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
95. Install the RH radio ignition interference capacitor and the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 90: Installing RH Radio Ignition Interference Capacitor And Stud Bolt

    Courtesy of FORD MOTOR CO.
96. Position the upper radiator hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 91: Installing Upper Radiator Hose Support Bracket And Nut

    Courtesy of FORD MOTOR CO.
97. Connect the RH CMP sensor electrical connector.
    Fig 92: Connecting RH CMP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
98. Install the special tool.
    Fig 93: Installing Special Tool

    Courtesy of FORD MOTOR CO.
99. Using a suitable floor crane, remove the engine from the engine stand.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
100. Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. 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.
Fig 94: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
Courtesy of FORD MOTOR CO.
101. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.
102. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
     Fig 95: Installing Crankshaft Rear Seal Retainer Plate And Loosely Installing Bolts

     Courtesy of FORD MOTOR CO.
103. Tighten the bolts in the sequence shown.
     • Tighten to 10 Nm (89 lb-in).
     Fig 96: Tightening Bolts In Sequence

     Courtesy of FORD MOTOR CO.
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 to remove all traces of old sealant.
104. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
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. 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.
Fig 97: Applying Silicone Gasket And Sealant At Crankshaft Rear Seal Retainer Plate-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
105. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
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. 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.
Fig 98: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
Courtesy of FORD MOTOR CO.
106. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
107. Install the oil pan gasket and the oil pan and loosely install the bolts.
     Fig 99: Installing Oil Pan Gasket And Oil Pan

     Courtesy of FORD MOTOR CO.
108. Tighten the bolts in 3 stages, in the sequence shown.
     • Stage 1: Tighten to 2 Nm (18 lb-in).
     • Stage 2: Tighten to 20 Nm (15 lb-ft).
     • Stage 3: Tighten an additional 60 degrees.
     Fig 100: Identifying Oil Pan Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Fig 101: Installing New Crankshaft Rear Seal Using Special Tools
Courtesy of FORD MOTOR CO.
109. Using the special tools, install a new crankshaft rear seal.
110. Using the special tools, install a new crankshaft rear oil slinger.
     Fig 102: Using Special Tools To Install New Crankshaft Rear Oil Slinger

     Courtesy of FORD MOTOR CO.
111. Install the flexplate and the 8 bolts in the sequence shown.
     • Tighten to 80 Nm (59 lb-ft).
     Fig 103: Installing Flexplate And Bolts In Sequence

     Courtesy of FORD MOTOR CO.