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Section 1154 (Engine -- 4.6L (2V)): 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 CHART

G03905862
 Installer, Connecting Rod 303-442 (T93P-6136-A)
G03901093
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
G03886827
 Installer, Crankshaft Front Oil Seal 303-635
G03920362
 Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
G03886455
 Holding Tool, Crankshaft 303-448 (T93P-6303-A)
G03948019
 Engine Lift Bracket Set 303-DS086 (D93P-6001-A)
G03948020
 Lifting Bracket Set, Engine 303-D074 (D91P-6001-A) or equivalent
G03905601
 Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
G03885486
 Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
G03886833
 Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
G03889585
 Strap Wrench 303-D055 (D85L-6000-A) or equivalent
G03885361
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
G03885376
 Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH)
G03920628
 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
G03879006
 Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent
MATERIAL CHART

Item Specification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C930-A
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket and Sealant TA-30 or equivalent WSE-M4G323-A4
Premium Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-C) or equivalent WSS-M97B41-A1
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A or equivalent ESE-M1C171-A
Instant Gel Adhesive TA-19 or equivalent WSK-M2G402-A4
Fig 1: Exploded View Of Engine - Upper End (1 Of 2)
G03947548Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Engine - Upper End (2 Of 2)
G03948030Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Engine Induction System
G03948031Courtesy of FORD MOTOR CO.
Fig 4: Exploded View Of Engine - Lower End (1 Of 2)
G03948032Courtesy of FORD MOTOR CO.
Fig 5: Exploded View Of Engine - Lower End (2 Of 2)
G03948033Courtesy of FORD MOTOR CO.
Fig 6: Exploded View Of Engine - Front End
G03948034Courtesy of FORD MOTOR CO.
NOTE: During engine assembly it may become necessary to check bearing clearances, end play, etc. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  1. Read the first character code information on the cylinder block face (1) and record the information.
    Fig 7: Locating Character Code Information On Cylinder Block Face
    G03948035Courtesy of FORD MOTOR CO.
  2. Read the first character on the No. 7 crankshaft counterweight and note it.
    Fig 8: Locating Character On No. 7 Crankshaft Counterweight
    G03948036Courtesy of FORD MOTOR CO.
  3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings chart 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 9: Bearing Select Fit Chart (Standard Bearings)
      G03886016Courtesy 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 chart to determine the required bearing grade for each main bearing.
    Fig 10: Bearing Select Fit Chart
    G04583822Courtesy of FORD MOTOR CO.
    5. 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. Lubricate with clean engine oil and install the crankshaft upper main bearings into the cylinder block.
  6. Install the crankshaft onto the upper thrust bearing and main bearings.
    Fig 11: Installing Crankshaft Onto Upper Crankshaft Main Bearings
    G03886018Courtesy of FORD MOTOR CO.
    7. 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 12: Installing Rear Main Bearing Cap
    G03948040Courtesy of FORD MOTOR CO.
  7. Install the rear main bearing cap.
  8. Install the crankshaft lower main bearings, thrust bearing and thrust washer 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.
  9. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.
    Fig 13: Installing Crankshaft Lower Main Bearings
    G03948041Courtesy of FORD MOTOR CO.
    10. NOTE: Make sure to tighten the bolts in 4 stages.
  10. Tighten the bolts in 4 stages.
    • Stage 1: Tighten bolts 1 through 20 in sequence to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 1 through 10 in sequence to 25 Nm (18 lb-ft).
    • Stage 3: Tighten bolts 11 through 20 in sequence to 40 Nm (30 lb-ft).
    • Stage 4: Tighten bolts 1 through 20 in sequence an additional 90 degrees
      Fig 14: Identifying Tightening Sequence Of Crankshaft Lower Main Bearings Bolts (1 Of 2)
      G03948042Courtesy of FORD MOTOR CO.
  11. Install and tighten the cross-mounted bolts in 2 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 15: Identifying Tightening Sequence Of Crankshaft Lower Main Bearings Bolts (2 Of 2)
      G03947994Courtesy of FORD MOTOR CO.
  12. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  13. Install the piston rings.
    Fig 16: Identifying Piston Rings
    G03947302Courtesy of FORD MOTOR CO.
  14. 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 Direction
    G03947324Courtesy of FORD MOTOR CO.
    15. 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 caps and pistons. Only one connecting rod, rod cap and piston is shown.
  15. Use the special tools to install the connecting rod with upper connecting rod bearing in place.
    • Lubricate the piston and ring with clean engine oil.
    • Lubricate the rod bearings with clean engine oil.
      Fig 18: Installing Connecting Rod With Upper Connecting Rod Bearing
      G03920388Courtesy of FORD MOTOR CO.
    16. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 19: Removing Special Tool
    G03920389Courtesy of FORD MOTOR CO.
  16. Once the connecting rod is seated on the crankshaft journal, remove the special tool.
    17. 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.
  17. Position the lower bearing and connecting rod cap and install the new bolts loosely.
    18. NOTE: Main caps are not shown for clarity.
  18. Tighten the bolts in 3 stages, using the sequence shown in Fig 20.
    • Stage 1: Tighten to 23 Nm (17 lb-ft).
    • Stage 2: Tighten to 43 Nm (32 lb-ft).
    • Stage 3: Tighten an additional 90-120 degrees.
      Fig 20: Tightening Bolts In Sequence
      G03920390Courtesy of FORD MOTOR CO.
  19. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown in Fig 21 to 10 Nm (89 lb-in).
    Fig 21: Installing Oil Pump
    G03948049Courtesy of FORD MOTOR CO.
    20. CAUTION: Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.
    CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of the sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.
    NOTE: RH shown, LH similar.
    Fig 22: Installing Head Gaskets Over Dowel Pins
    G03948050Courtesy of FORD MOTOR CO.
  20. Install the head gaskets over the dowel pins.
    21. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
    CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
    NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.
  21. Tighten the LH cylinder head bolts in 6 stages in the sequence shown in Fig 23.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    • Stage 3: Back out 1 full turn (360 degrees).
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees (1/4 turn).
    • Stage 6: Tighten an additional 90 degrees (1/4 turn).
      Fig 23: Tightening LH Cylinder Head Bolts In Sequence
      G03948051Courtesy of FORD MOTOR CO.
    22. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.
    CAUTION: The gasket sealing surfaces on the cylinder head and the cylinder block must be clean. For additional information, refer to CYLINDER HEADS .
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
    NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.
  22. Tighten the RH cylinder head bolts in 6 stages in the sequence shown in Fig 24.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    • Stage 3: Back out 1 full turn (360 degrees).
    • Stage 4: Tighten to 40 Nm (30 lb-ft).
    • Stage 5: Tighten an additional 90 degrees (1/4 turn).
    • Stage 6: Tighten an additional 90 degrees (1/4 turn).
      Fig 24: Tightening RH Cylinder Head Bolts In Sequence
      G03948052Courtesy of FORD MOTOR CO.
    23. NOTE: Lubricate O-ring seal with clean engine oil.
  23. Install the oil level indicator tube.
    • Install a new O-ring seal on the oil level indicator tube.
    • Install the oil level indicator tube.
    • Install the bolt and tighten it to 10 Nm (89 lb-in).
      Fig 25: Locating Oil Level Indicator Tube Mounting Bolt
      G03906387Courtesy of FORD MOTOR CO.
  24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown in Fig 26 to 20 Nm (15 lb-ft).
    Fig 26: Installing RH Exhaust Manifold Gaskets And Exhaust Manifold
    G03947686Courtesy of FORD MOTOR CO.
  25. Install the RH exhaust manifold heat shield and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 27: Installing RH Exhaust Manifold Heat Shield And Bolts
      G03947753Courtesy of FORD MOTOR CO.
  26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown in Fig 28 to 20 Nm (15 lb-ft).
    Fig 28: Tightening Nuts In Sequence Shown
    G03947682Courtesy of FORD MOTOR CO.
  27. Install the LH exhaust manifold heat shield and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 29: Installing LH Exhaust Manifold Heat Shield And Bolts
      G03947755Courtesy of FORD MOTOR CO.
    28. 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.
    NOTE: The following 2 steps must be performed on both hydraulic chain tensioners.
    Fig 30: Compressing Tensioner Plunger Using Edge Of Vise
    G03885344Courtesy of FORD MOTOR CO.
  28. Compress the tensioner plunger, using a vise.
  29. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 31: Installing Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  30. If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.
    Fig 32: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
    31. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position show in Fig 33 or severe piston and/or valve damage will occur.
    Fig 33: Positioning Crankshaft
    G03947638Courtesy of FORD MOTOR CO.
  31. Using the special tool, position the crankshaft.
  32. Install the crankshaft sprocket with the flange facing forward.
    Fig 34: Installing Crankshaft Sprocket With Flange Facing Forward
    G03948062Courtesy of FORD MOTOR CO.
  33. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the bolts to 10 Nm (89 lb-in).
    3. Position the RH timing chain guide.
    4. Install and tighten the bolts to 10 Nm (89 lb-in).
      Fig 35: Installing RH Timing Chain Guide
      G03948063Courtesy of FORD MOTOR CO.
  34. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    Fig 36: Identifying Timing Mark
    G04583473Courtesy of FORD MOTOR CO.
  35. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 37: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
    36. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
    Fig 38: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
  36. Position the LH timing chain on the camshaft sprocket. Make sure the copper-colored link aligns with the camshaft sprocket timing mark.
    37. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  37. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 39: Installing LH Timing Chain Tensioner
      G03947647Courtesy of FORD MOTOR CO.
  38. Remove the retaining clip from the LH timing chain tensioner.
    Fig 40: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  39. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 41: Aligning Copper (Marked) Link With Timing Mark On Sprocket
    G03948189Courtesy of FORD MOTOR CO.
    40. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
    Fig 42: Aligning Copper (Marked) Link With Timing Marks On Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  40. Position the RH timing chain on the camshaft sprocket. Make sure the copper-colored link aligns with the camshaft sprocket timing mark.
  41. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 43: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
      G03947653Courtesy of FORD MOTOR CO.
  42. Remove the retaining clip from the RH timing chain tensioner.
    Fig 44: Timing Chain Tensioner Retaining Clip
    G03881591Courtesy of FORD MOTOR CO.
  43. As a post-check, verify correct alignment of all timing marks.
    Fig 45: Checking Timing Marks
    G03947655Courtesy of FORD MOTOR CO.
  44. Install the crankshaft sensor ring on the crankshaft.
    Fig 46: Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
    45. NOTE: If the bolt is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.
    Fig 47: Applying Bead Of Silicone Gasket And Sealant Along Head-To-Block Surface
    G03921154Courtesy of FORD MOTOR CO.
  45. Apply a bead of silicone gasket and sealant along the head-to-block surface as specified.
  46. Install new engine front cover gaskets on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 48: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  47. Tighten the front cover bolts and stud bolts in the sequence shown in Fig 49 to 25 Nm (18 lb-ft).
    Fig 49: Tightening Front Cover Bolts And Stud Bolts In Sequence
    G03948077Courtesy of FORD MOTOR CO.
  48. Lubricate the front cover and the front oil seal inner lip with clean engine oil.
    Fig 50: Installing Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  49. Using the special tool, install the front oil seal into the engine front cover.
    Fig 51: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    50. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 52: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  50. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  51. Using the special tool, install the crankshaft pulley.
    Fig 53: Installing Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
    52. NOTE: Use special tool 303-D055 to hold the crankshaft pulley.
  52. Install the bolt and washer. Tighten the 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 54: Installing Crankshaft Pulley Bolt & Washer
      G04672695Courtesy of FORD MOTOR CO.
  53. Rotate the camshaft until the lobe is in the upward position.
    Fig 55: Rotating Camshaft
    G03881960Courtesy of FORD MOTOR CO.
  54. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 56: Installing Special Tool Between Valve Spring Coils
    G03947787Courtesy of FORD MOTOR CO.
  55. Use the special tool to compress the valve spring and install the camshaft roller followers.
    Fig 57: Compressing Valve Spring
    G03947788Courtesy of FORD MOTOR CO.
  56. Install the spark plugs.
    • Tighten to 18 Nm (13 lb-ft).
      Fig 58: Installing Spark Plugs
      G03948086Courtesy of FORD MOTOR CO.
  57. Inspect the LH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  58. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the valve cover.
    Fig 59: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    59. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 60: Applying Silicone Gasket And Sealant To Left Valve Cover Gasket Surface
    G03947580Courtesy of FORD MOTOR CO.
  59. Apply silicone gasket and sealant to the left valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.
  60. Install the left valve cover and tighten the bolts in the sequence shown in Fig 61.
    • Tighten to 10 Nm (89 lb-in).
      Fig 61: Installing Left Valve Cover
      G03947581Courtesy of FORD MOTOR CO.
  61. Inspect the RH valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  62. If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the valve cover.
    Fig 62: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    63. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 63: Applying Silicone Gasket And Sealant To Right Valve Cover Gasket Surface
    G03947588Courtesy of FORD MOTOR CO.
  63. Apply silicone gasket and sealant to the right valve cover gasket surface, in 2 places, where the engine front cover meets the cylinder head.
  64. Install the right valve cover and tighten the bolts in the sequence shown in Fig 64.
    • Tighten to 10 Nm (89 lb-in).
      Fig 64: Installing Right Valve Cover
      G03947589Courtesy of FORD MOTOR CO.
  65. Install the oil pump screen cover and tube spacer.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 65: Installing Oil Pump Screen Cover And Tube Spacer
      G03948093Courtesy of FORD MOTOR CO.
    66. NOTE: Oil scraper not shown for clarity.
  66. Position the oil pump screen cover and tube and install the bolts.
    1. Tighten to 10 Nm (89 lb-in).
    2. Tighten to 25 Nm (18 lb-ft).
      Fig 66: Positioning Oil Pump Screen Cover
      G03948094Courtesy of FORD MOTOR CO.
    67. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    NOTE: The silicone must be applied on the groove along the retainer plate.
    Fig 67: Applying Bead Of Silicone Gasket And Sealant Around Crankshaft Rear Seal Retainer Sealing Surface
    G03881975Courtesy of FORD MOTOR CO.
  67. Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
  68. Install the rear oil seal retainer and install the 6 bolts finger tight.
    Fig 68: Identifying Crankshaft Rear Oil Seal Retainer
    G04583880Courtesy of FORD MOTOR CO.
  69. Tighten the bolts in the sequence shown in Fig 69 to 10 Nm (89 lb-in).
    Fig 69: Identifying Tightening Sequence Of Retainer Plate Bolts
    G04583881Courtesy of FORD MOTOR CO.
    70. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 70: Identifying Area For Applying Bead Of Silicone Gasket And Sealant
    G04583522Courtesy of FORD MOTOR CO.
  70. Apply silicone gasket and sealant in 2 places.
    71. NOTE: If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 71: Identifying Area For Applying Silicone Gasket And Sealant
    G03885463Courtesy of FORD MOTOR CO.
  71. Apply silicone gasket and sealant in 2 places.
  72. Position the new oil pan gasket and the oil pan and loosely install the bolts.
    Fig 72: Installing Oil Pan Gasket And Oil Pan
    G03947692Courtesy of FORD MOTOR CO.
  73. Tighten the bolts in 3 stages, in the sequence shown in Fig 73.
    • 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 73: Identifying Bolt Tightening Sequence
      G03920110Courtesy of FORD MOTOR CO.
  74. Install the RH engine support insulator bracket and the bolts.
    • Tighten to 72 Nm (53 lb-ft).
      Fig 74: Installing RH Engine Support Insulator Bracket
      G03947777Courtesy of FORD MOTOR CO.
  75. Install the LH engine support insulator bracket and the bolts.
    • Tighten to 72 Nm (53 lb-ft).
      Fig 75: Installing LH Engine Support Insulator Bracket
      G03947776Courtesy of FORD MOTOR CO.
  76. Install the coolant tube and the nut.
    • Inspect and install new O-ring seals as necessary.
    • Lubricate the O-ring seals with clean engine coolant.
    • Tighten to 10 Nm (89 lb-in).
      Fig 76: Installing O-Ring Seals
      G03948104Courtesy of FORD MOTOR CO.
  77. Install the knock sensor (KS) and the bolts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 77: Installing Knock Sensor (KS) And Bolts
      G03947963Courtesy of FORD MOTOR CO.
  78. Inspect the O-ring seals. Install new O-ring seals if necessary.
    Fig 78: Installing O-Ring Seals
    G03948106Courtesy of FORD MOTOR CO.
  79. Connect the heater coolant hose.
    Fig 79: Connecting Heater Coolant Hose
    G03947962Courtesy of FORD MOTOR CO.
  80. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 80: Installing Ground Wire And Bolt
      G03947961Courtesy of FORD MOTOR CO.
  81. Install new intake manifold gaskets.
    Fig 81: Installing Intake Manifold Gaskets
    G03947775Courtesy of FORD MOTOR CO.
  82. Install the intake manifold and tighten the bolts in the sequence shown in Fig 82 to 25 Nm (18 lb-ft).
    Fig 82: Installing Intake Manifold
    G03947565Courtesy of FORD MOTOR CO.
    83. NOTE: Lubricate the O-ring seal with clean engine coolant.
    Fig 83: Installing Thermostat Housing
    G03947773Courtesy of FORD MOTOR CO.
  83. Install the thermostat housing and the bolts.
    84. NOTE: Apply dielectric compound to the inside of the coil boots.
  84. Install all 8 ignition coils and the bolts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 84: Installing Ignition Coils And Bolts
      G03947564Courtesy of FORD MOTOR CO.
  85. Position the fuel charging wiring harness on the top of the engine.
    • Connect the harness locators to the engine.
      Fig 85: Connecting Harness Locators To Engine
      G03948113Courtesy of FORD MOTOR CO.
  86. Position the starter wiring harness and connect the wiring harness retainers.
    Fig 86: Positioning Starter Wiring Harness
    G03948114Courtesy of FORD MOTOR CO.
  87. Connect the ground wire.
    Fig 87: Connecting Ground Wire
    G03947560Courtesy of FORD MOTOR CO.
  88. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 88: Installing Bolt
      G03947744Courtesy of FORD MOTOR CO.
  89. Connect the 2 fuel charging wiring harness retainers and the 8 electrical connectors.
    Fig 89: Connecting Fuel Charging Wiring Harness Retainers
    G03947562Courtesy of FORD MOTOR CO.
  90. Connect the 2 fuel charging wiring harness retainers and the 8 electrical connectors.
    Fig 90: Connecting Fuel Charging Wiring Harness Retainers And Electrical Connectors
    G03947561Courtesy of FORD MOTOR CO.
  91. Install the throttle body adapter and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 91: Installing Throttle Body Adapter
      G03947767Courtesy of FORD MOTOR CO.
  92. Connect the coolant hose.
    Fig 92: Connecting Coolant Hose
    G03947766Courtesy of FORD MOTOR CO.
  93. Connect the coolant hoses.
    Fig 93: Connecting Coolant Hoses
    G03947765Courtesy of FORD MOTOR CO.
  94. Connect the KS electrical connector and the wiring harness pin-type retainer.
    Fig 94: Connecting KS Electrical Connector
    G03948122Courtesy of FORD MOTOR CO.
  95. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 95: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03947763Courtesy of FORD MOTOR CO.
  96. Connect the EGR system module and fuel pressure sensor electrical connectors.
    Fig 96: Connecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
    G03947762Courtesy of FORD MOTOR CO.
  97. Position the vacuum harness on the engine and connect the EGR system module and fuel pressure sensor vacuum fittings.
    Fig 97: Connecting EGR System Module And Fuel Pressure Sensor Vacuum Fittings
    G03947558Courtesy of FORD MOTOR CO.
  98. Install the positive crankcase ventilation (PCV) tube and connect the vacuum tube to the throttle body adapter.
    Fig 98: Connecting Vacuum Tube To Throttle Body Adapter
    G03947760Courtesy of FORD MOTOR CO.
  99. Connect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
    Fig 99: Connecting Throttle Position (TP) Sensor
    G03947759Courtesy of FORD MOTOR CO.
  100. Install the brake booster vacuum hose and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 100: Installing Brake Booster Vacuum Hose And Bolt
      G03947758Courtesy of FORD MOTOR CO.
  101. Install the EGR tube to the exhaust manifold and to the EGR system module.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 101: Installing EGR Tube To Exhaust Manifold
      G03947752Courtesy of FORD MOTOR CO.
    102. 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.
  102. Install the water pump.
    1. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump.
    2. Position the coolant pump into the engine block.
    3. Install the bolts and tighten to 25 Nm (18 lb-ft).
      Fig 102: Positioning Coolant Pump Into Engine Block
      G03948130Courtesy of FORD MOTOR CO.
  103. Position the coolant pump pulley on the coolant pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 103: Positioning Coolant Pump Pulley On Coolant Pump
      G03947934Courtesy of FORD MOTOR CO.
  104. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 104: Installing Crankshaft Position (CKP) Sensor And Bolt
      G03947933Courtesy of FORD MOTOR CO.
  105. Install the drive belt tensioner and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 105: Installing Drive Belt Tensioner
      G03947932Courtesy of FORD MOTOR CO.
  106. Install the camshaft position (CMP) sensor and the bolt and connect the electrical connector.
    • Tighten to 10 Nm (89 lb-in).
      Fig 106: Installing Camshaft Position (CMP) Sensor
      G03947751Courtesy of FORD MOTOR CO.
  107. Install the generator and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 107: Installing Generator And Bolts
      G03947750Courtesy of FORD MOTOR CO.
  108. Install the upper generator bracket and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 108: Installing Upper Generator Bracket And Bolts
      G03947929Courtesy of FORD MOTOR CO.
  109. Connect the electrical connectors, install the nut and attach the wiring harness retainer.
    • Tighten to 8 Nm (71 lb-in).
      Fig 109: Connecting Electrical Connectors
      G03947748Courtesy of FORD MOTOR CO.
  110. Install the idler pulleys and the bolts.
    • Tightens to 25 Nm (18 lb-ft).
      Fig 110: Installing Idler Pulleys And Bolts
      G03947747Courtesy of FORD MOTOR CO.
  111. Install the upper radiator hose bracket, the radio interference capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 111: Installing Upper Radiator Hose Bracket
      G03947621Courtesy of FORD MOTOR CO.
  112. Install the A/C compressor and the nuts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 112: Installing A/C Compressor And Nuts
      G03885760Courtesy of FORD MOTOR CO.
  113. Attach the wiring harness retainer to the A/C tube.
    Fig 113: Attaching Wiring Harness Retainer To A/C Tube
    G03947743Courtesy of FORD MOTOR CO.
  114. Position the electrical harness and connect the retainers.
    Fig 114: Positioning Electrical Harness
    G03948142Courtesy of FORD MOTOR CO.
  115. Install the crankcase air inlet tube.
    Fig 115: Installing Crankcase Air Inlet Tube
    G03947745Courtesy of FORD MOTOR CO.
  116. Connect the A/C compressor and CKP sensor electrical connectors.
    Fig 116: Connecting A/C Compressor And CKP Sensor Electrical Connectors
    G03947920Courtesy of FORD MOTOR CO.
  117. Install the power steering reservoir bracket, radio interference capacitor, ground cable and nut.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 117: Installing Power Steering Reservoir Bracket, Radio Interference Capacitor, Ground Cable And Nut
      G03947739Courtesy of FORD MOTOR CO.
  118. Using the special tool, install a new seal on the power steering pressure hose fitting.
    Fig 118: Installing Seal On Power Steering Pressure Hose Fitting
    G03947475Courtesy of FORD MOTOR CO.
  119. Install the power steering pump and the bolts.
    • To install, tighten to 20 Nm (15 lb-ft).
      Fig 119: Installing Power Steering Pump
      G03947738Courtesy of FORD MOTOR CO.
  120. Connect the return and pressure hoses to the power steering pump.
    • Tighten to 65 Nm (48 lb-ft).
      Fig 120: Connecting Return And Pressure Hoses
      G03947737Courtesy of FORD MOTOR CO.
  121. Install the power steering hose support bracket and the nuts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 121: Installing Power Steering Hose Support Bracket
      G03947620Courtesy of FORD MOTOR CO.
    122. NOTE: Clean and inspect the mating surfaces and install new gaskets.
  122. Position the oil filter adapter, install the bolts and connect the oil pressure electrical connector.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 122: Connecting Oil Pressure Electrical Connector
      G03947915Courtesy of FORD MOTOR CO.
  123. Install the oil filter.
  124. Install the wiring harness bracket and nuts.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 123: Installing Wiring Harness Bracket And Nuts
      G03947735Courtesy of FORD MOTOR CO.
  125. Install the drive belt.
    126. NOTE: RH is shown, LH is similar.
    Fig 124: Installing Engine Lift Brackets
    G03947896Courtesy of FORD MOTOR CO.
  126. Install the engine lift brackets.
  127. Attach the special tool to a floor crane and the engine and remove the engine from the engine stand.
    Fig 125: Removing Engine From Engine Stand
    G03947898Courtesy of FORD MOTOR CO.
  128. Using the special tools, install the crankshaft rear seal.
    Fig 126: Installing Crankshaft Rear Oil Seal
    G04583928Courtesy of FORD MOTOR CO.
  129. Using the special tools, install the crankshaft rear oil slinger.
    Fig 127: Installing Crankshaft Rear Oil Slinger
    G03920154Courtesy of FORD MOTOR CO.
  130. Install the spacer plate.
    Fig 128: Installing Spacer Plate
    G03948156Courtesy of FORD MOTOR CO.
    131. CAUTION: Special bolts are used for flexplate installation. Do not use standard bolts.
  131. Position the flexplate and install the bolts finger tight.
    • Tighten the bolts in the sequence shown in Fig 129 to 80 Nm (59 lb-ft).
      Fig 129: Identifying Tightening Sequence Of Flexplate Bolts
      G03947697Courtesy of FORD MOTOR CO.
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