Section 1721 (Engine - 3.0L (4V)): Assembly: Engine

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S)

Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A)
Courtesy of FORD MOTOR CO.	Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A)
Courtesy of FORD MOTOR CO.	Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH)
Courtesy of FORD MOTOR CO.	Protector, Camshaft Oil Seal 303-463 (T91P-6256-AH)
Courtesy of FORD MOTOR CO.	Installer, Camshaft Oil Seal 303-464 (T94P-6256-BH)
Courtesy of FORD MOTOR CO.	Installer, Power Steering Pump Pulley 211-185 (T91P-3A733-A)
Courtesy of FORD MOTOR CO.	Lifting Brackets, Engine 303-050 (T70P-6000)
Courtesy of FORD MOTOR CO.	Lifting Brackets, Engine 134-00243 or equivalent
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket Set 303-1140
Courtesy of FORD MOTOR CO.	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
Courtesy of FORD MOTOR CO.	Strap Wrench 303-D055 (D85L-6000-A)

MATERIAL

Item	Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent	WSS-M2C930-A
Motorcraft Metal Surface Cleaner ZC-21	WSE-M5B392-A
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Thread Sealant with PTFE TA-24	WSK-M2G350-A2
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color)	WSS-M97B51-A1

Fig 1: Identifying Engine Components (Items 1-37)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Engine Components (Items 1-18)

Courtesy of FORD MOTOR CO.

Fig 3: Part Description Chart (Items 19-41)

Courtesy of FORD MOTOR CO.

CAUTION: 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: If the oil pan was removed during engine disassembly, it must be installed after the engine and transaxle are assembled and the transaxle-to-engine bolts are installed. Failure to follow this assembly sequence can result in engine oil leaks.

Install the oil separator cover, a new gasket and the bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 4: Locating Oil Separator Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Position the new gaskets and the LH and RH cylinder heads. Install new bolts and tighten in the sequence shown in 6 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten to 90 Nm (66 lb-ft).
- Stage 3: Loosen one full turn.
- Stage 4: Tighten to 40 Nm (30 lb-ft).
- Stage 5: Tighten 90 degrees.
- Stage 6: Tighten 90 degrees.
  
  Fig 5: Identifying Tightening Sequence Of Cylinder Heads Bolts
  Courtesy of FORD MOTOR CO.
Position the oil pump and install the 4 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 6: Locating Tightening Sequence Of Oil Pump Bolts
  Courtesy of FORD MOTOR CO.
If removed, install the crankshaft key into the keyway on the crankshaft.

Fig 7: Locating Crankshaft Key
Courtesy of FORD MOTOR CO.
Install the crankshaft pulley bolt and washer and rotate the crankshaft keyway to the 11 o'clock position to locate top dead center (TDC).

Fig 8: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
Apply clean engine oil to the LH and RH camshaft roller followers.

CAUTION: The camshaft roller followers must be installed in their original positions.

NOTE: RH shown, LH similar.

Fig 9: Locating Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Install the LH and RH camshaft roller followers.
Position the variable camshaft timing (VCT) actuators onto the intake camshafts.
- Install the bolts finger-tight.
  
  Fig 10: Locating Variable Camshaft Timing Actuators Onto Intake Camshafts
  Courtesy of FORD MOTOR CO.
Lubricate the RH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
- Align the RH camshafts as shown.
  
  Fig 11: Aligning RH Camshafts
  Courtesy of FORD MOTOR CO.

CAUTION: The camshaft caps must be installed in their original positions or damage to the engine may occur.

CAUTION: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.

NOTE: Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.

Install the RH camshaft bearing caps.
- Loosely install the bolts.
  
  Fig 12: Locating RH Camshaft Bearing Caps
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.

Install the RH camshaft bearing thrust caps.
- Loosely install the bolts.
  
  Fig 13: Locating RH Camshaft Bearing Thrust Caps
  Courtesy of FORD MOTOR CO.
Tighten the RH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 14: Locating Tightening Sequence Of RH Camshaft Bearing Cap Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the camshaft to rotate from the neutral position while removing the VCT actuator.

NOTE: Install a 3/8-inch ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.

Fig 15: Locating VCT Actuator And Bolt

Courtesy of FORD MOTOR CO.

Tighten the RH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.
Lubricate the LH camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
- Align the LH camshafts as shown.
  
  Fig 16: Aligning LH Camshafts
  Courtesy of FORD MOTOR CO.

CAUTION: The camshaft caps must be installed in their original positions or damage to the engine may occur.

CAUTION: Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.

NOTE: Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.

Install the LH camshaft bearing caps.
- Loosely install the bolts.
  
  Fig 17: Locating LH Camshaft Bearing Caps
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.

Install the LH camshaft bearing thrust caps.
- Loosely install the bolts.
  
  Fig 18: Locating LH Camshaft Bearing Thrust Caps
  Courtesy of FORD MOTOR CO.
Tighten the LH camshaft bearing cap bolts in the sequence shown to 10 Nm (89 lb-in).

Fig 19: Locating Tightening Sequence Of LH Camshaft Bearing Cap Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the camshaft to rotate from the neutral position while tightening VCT actuator bolt.

NOTE: Install a 3/8-inch ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.

Fig 20: Locating VCT Actuator And Bolt

Courtesy of FORD MOTOR CO.

Tighten the LH VCT actuator bolt to 40 Nm (30 lb-ft) plus an additional 90 degrees.

NOTE: Clean the sealing surface with metal surface cleaner before installing a new press-in-place gasket.

Install the camshaft oil seal retainer and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 21: Locating Camshaft Oil Seal Retainer And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the seal lip and seal bore before installing the seal.

Fig 22: Identifying Special Tools (303-463, 303-464 And 211-185)

Courtesy of FORD MOTOR CO.

Using the special tools, install a new camshaft oil seal.
Remove the crankshaft pulley bolt and washer.

Fig 23: Locating Crankshaft Damper Bolt
Courtesy of FORD MOTOR CO.
Install the crankshaft sprockets with the timing marks out.

Fig 24: Locating Marks On Crankshaft Sprockets
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 25: Identifying Chain Tensioner In Soft-Jawed Vise

Courtesy of FORD MOTOR CO.

Position the chain tensioner in a soft-jawed vise.

NOTE: LH shown, RH similar.

Fig 26: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem

Courtesy of FORD MOTOR CO.

Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Slowly compress the timing chain tensioner.
Retain the tensioner piston with a 1.5 mm (0.05 in) wire or paper clip.

Fig 27: Retaining Tensioner Piston With 1.5-mm (0.06-in) Wire Or Paper Clip
Courtesy of FORD MOTOR CO.
If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the LH and RH timing chains.
1. Mark any link to use as the crankshaft timing mark.
2. Starting with the crankshaft timing mark, count counterclockwise 29 links and mark the link.
3. Continue counting counterclockwise to link 42 and mark the link.
  
  Fig 28: Identifying Marking On Chains
  Courtesy of FORD MOTOR CO.
Verify that the LH camshafts are correctly positioned.

Fig 29: Locating LH Camshafts Position
Courtesy of FORD MOTOR CO.
Install the variable camshaft timing (VCT) assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 30: Locating Variable Camshaft Timing (VCT) Assembly Bolts
  Courtesy of FORD MOTOR CO.
Install the LH timing chain.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
  
  Fig 31: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets
  Courtesy of FORD MOTOR CO.
Install the LH timing chain tensioner arm and the LH timing chain tensioner.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 32: Identifying LH Tensioner Arm, Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Install the crankshaft pulley bolt and washer and rotate the crankshaft clockwise 120 degrees until the crankshaft key way is in the 3 o'clock position.

Fig 33: Locating Crankshaft Keyway
Courtesy of FORD MOTOR CO.
Verify that the RH camshafts are correctly positioned.

Fig 34: Locating RH Camshafts Position
Courtesy of FORD MOTOR CO.
Install the RH VCT assembly and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 35: Locating RH VCT Assembly And Bolts
  Courtesy of FORD MOTOR CO.
Install the RH timing chain.
- Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
  
  Fig 36: Aligning Marks On Timing Chain With Marks On Camshaft And Crankshaft Sprockets
  Courtesy of FORD MOTOR CO.
Install the RH timing chain tensioner and tensioner arm.
1. Install the tensioner arm.
2. Position the tensioner.
3. Install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 37: Identifying Tensioner Arm, Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Remove the LH and RH timing chain tensioner piston retaining wires.
Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).

CAUTION: Failure to verify correct timing drive component alignment will result in severe engine damage.

Verify the timing with the following steps.
1. There should be 12 chain links between the camshaft timing marks.
2. There should be 27 chain links between the camshaft and the crankshaft timing marks.
3. There should be 30 chain links between the camshaft and the crankshaft timing marks.
  
  Fig 38: Locating Align Marks On Chain
  Courtesy of FORD MOTOR CO.
Remove the crankshaft pulley bolt and washer.

Fig 39: Identifying Damper Bolt
Courtesy of FORD MOTOR CO.

CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 30RFF only (orange in color).

Fig 40: Identifying Ignition Pulse Wheel

Courtesy of FORD MOTOR CO.

Install the ignition pulse wheel.
Install 3 new gaskets in the front cover.

NOTE: Clean the sealing surfaces with metal surface cleaner before applying gasket and sealant.

NOTE: The front cover must be installed and the bolts tightened within 4 minutes of sealant application.

Fig 41: Locating Silicone Gasket And Sealant On Cylinder Block

Courtesy of FORD MOTOR CO.

Apply a 6 mm (0.23 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.

NOTE: Fasteners 1 and 13 are stud bolts.

Position the engine front cover and install the 14 bolts and 2 stud bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).
  
  Fig 42: Locating Tighten Sequence Of Engine Front Cover Bolts
  Courtesy of FORD MOTOR CO.
Apply clean engine oil to the seal lip and seal bore before installing the seal.
Using the special tools, install a new crankshaft front seal.

Fig 43: Installing Crankshaft Seal Using Special Tools (303-335 And 303-102)
Courtesy of FORD MOTOR CO.

NOTE: Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealant.

NOTE: The crankshaft pulley must be installed and the bolt tightened within 4 minutes of applying the silicone gasket and sealer.

Fig 44: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the end of the keyway slot.

NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Fig 45: Identifying Special Tools (303-102 And 303-335)

Courtesy of FORD MOTOR CO.

Using the special tool, install the crankshaft pulley.
Install the bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 46: Identifying Special Tools (303-S055) And Bolt
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the 2 idler pulleys.
- Tighten the tensioner bolt to 45 Nm (33 lb-ft).
- Tighten the idler pulley bolts to 25 Nm (18 lb-ft).
  
  Fig 47: Locating Accessory Drive Belt Tensioner, Idler Pulleys And Bolts
  Courtesy of FORD MOTOR CO.
Instal the oil pan baffle and the 8 nuts.
- Tighten the oil pan baffle nuts in 2 stages.
  - Stage 1: Tighten the 4 smaller nuts to 5 Nm (44 lb-in) and the larger nuts to 15 Nm (11 lb-ft).
  - Stage 2: Tighten all 8 nuts an additional 45 degrees.
    
    Fig 48: Locating Oil Pan Baffle And Nuts
    Courtesy of FORD MOTOR CO.
Install a new O-ring seal on the oil pump screen and pickup tube.
- Lubricate with clean engine oil.
  
  Fig 49: Locating O-Ring Seal
  Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 50: Locating Oil Pump Screen Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.

Install the LH and RH spark plugs.
- Tighten to 15 Nm (11 lb-ft).
  
  Fig 51: Locating Spark Plugs
  Courtesy of FORD MOTOR CO.

NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

Fig 52: Locating Silicone Gasket Sealant

Courtesy of FORD MOTOR CO.

Apply a an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints and the cam seal retainer-to-cylinder head joints.
Position the LH valve cover and install the bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 53: Locating Tightening Sequence Of LH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

Install the 3 LH coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 54: Locating LH Coil-On-Plug Assemblies And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.

Fig 55: Locating Silicone Gasket Sealant

Courtesy of FORD MOTOR CO.

Apply an 8 mm (0.31 in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
Position the RH valve cover and install the bolts and stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 56: Locating Tightening Sequence Of RH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.

Install the 3 RH coil-on-plug assemblies and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 57: Locating RH Coil-On-Plug Assemblies And Bolts
  Courtesy of FORD MOTOR CO.
If equipped, install the block heater.
- Tighten to 41 Nm (30 lb-ft).
  
  Fig 58: Locating Block Heater
  Courtesy of FORD MOTOR CO.

NOTE: Apply thread sealant with PTFE to the oil pressure sender threads.

Install the oil pressure sender.
- Tighten to 14 Nm (10 lb-ft).
  
  Fig 59: Locating Oil Pressure Sender
  Courtesy of FORD MOTOR CO.
Install the knock sensor (KS) and the bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 60: Locating Knock Sensor (KS) And Bolt
  Courtesy of FORD MOTOR CO.
Install the coolant pump and the 3 bolts.
- Tighten to 10 Nm (89 lb-in) then rotate 90 degrees.
  
  Fig 61: Locating Coolant Pump And Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: The pulley is pressed on flush to the end of the camshaft.

Fig 62: Identifying Special Tools (211-185 And 303-S455) And Coolant Pump Drive Pulley

Courtesy of FORD MOTOR CO.

Using the special tool, install the coolant pump drive pulley.
Install the coolant pump belt on the coolant pump pulley and position it on the coolant pump drive pulley.

Fig 63: Locating Coolant Pump Belt On Coolant Pump Pulley
Courtesy of FORD MOTOR CO.

CAUTION: Do not use any screwdrivers, pliers or other metal objects that could cause damage to the belt or pulley while installing the belt.

Rotate the crankshaft clockwise to seat the coolant pump belt on the coolant pump drive belt pulley.
If equipped, install the coolant pump drive pulley cover and the 2 nuts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 64: Locating Coolant Pump Drive Pulley Cover Nuts
  Courtesy of FORD MOTOR CO.
Connect the coolant pump hose to the cylinder block outlet.

Fig 65: Identifying Coolant Pump Hose To Cylinder Block Outlet
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seals with clean engine coolant.

Install new O-ring seals, the bypass tube, bolt and stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 66: Locating O-Ring Seals, Bypass Tube, Bolt And Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the thermostat housing.

Fig 67: Locating Thermostat Housing
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the lower intake manifold and install the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 68: Identifying Tightening Sequence Of Lower Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Install a new O-ring on the oil level indicator tube. Apply clean engine oil to the O-ring.

Fig 69: Locating O-Ring On Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Position the oil level indicator and tube and install the stud bolt.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 70: Locating Oil Level Indicator, Tube And Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the LH catalytic converter bracket and the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 71: Locating LH Catalytic Converter Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install 6 new RH catalytic converter studs.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 72: Locating Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Install a new gasket, the RH catalytic converter and 6 new nuts.
- Tighten to 20 Nm (15 lb-ft) in the sequence shown.
  
  Fig 73: Identifying Tightening Sequence Of RH Catalytic Converter Nuts
  Courtesy of FORD MOTOR CO.
Position the power steering pump and reservoir assembly onto the engine and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 74: Locating Power Steering Pump And Reservoir Assembly Engine Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 power steering reservoir nuts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 75: Locating Power Steering Reservoir Nuts
  Courtesy of FORD MOTOR CO.
Install the A/C compressor bracket and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 76: Locating A/C Compressor Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 77: Locating A/C Compressor Bolts
  Courtesy of FORD MOTOR CO.
Install the generator and the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 78: Locating Generator Bolts
  Courtesy of FORD MOTOR CO.
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.

Fig 79: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the coolant bypass stud bolt.

Fig 80: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Position the wiring harness onto the engine and connect the engine coolant temperature (ECT) sensor electrical connector.

Fig 81: Locating Coolant Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the KS electrical connector.

Fig 82: Locating KS Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the positive crankcase ventilation (PCV) valve electrical connector.

Fig 83: Locating Positive Crankcase Ventilation Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the RH heated oxygen sensor (HO2S) electrical connector.

Fig 84: Locating RH Heated Oxygen Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the power steering stud bolt.

Fig 85: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Install the radio frequency interference capacitor and the nut.
- Tighten to 6 Nm (53 lb-in).
Connect the RH VCT solenoid and LH camshaft position (CMP) sensor electrical connectors.
- Attach the 2 wiring harness retainers to the valve cover stud bolts.
  
  Fig 86: Locating RH VCT Solenoid And LH Camshaft Position Sensor Electrical Connectors
  Courtesy of FORD MOTOR CO.
Connect the 3 RH coil-on-plug electrical connectors.
- Attach the 2 wiring harness pin-type retainers to the valve cover.
  
  Fig 87: Locating RH Coil-On-Plug Electrical Connectors
  Courtesy of FORD MOTOR CO.

NOTE: Only one wiring harness retainer is shown, other wiring harness retainer is similar.

Fig 88: Locating Fuel Rail Wiring Harness Retainer

Courtesy of FORD MOTOR CO.

Attach the 2 wiring harness retainers to the fuel rail.
Connect the 6 (3 shown) fuel injector electrical connectors.

Fig 89: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer to the LH valve cover stud bolt.

Fig 90: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the 3 LH coil-on-plug electrical connectors.
- Attach the 2 wiring harness pin-type retainers to the valve cover.
  
  Fig 91: Locating LH Coil-On-Plug Electrical Connectors
  Courtesy of FORD MOTOR CO.
Attach the 3 wiring harness retainers to the valve cover stud bolts.

Fig 92: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the LH VCT solenoid and LH CMP sensor electrical connectors.
- Attach the 2 wiring harness retainers to the valve cover stud bolts.
  
  Fig 93: Locating LH VCT Solenoid And LH CMP Sensor Electrical Connectors
  Courtesy of FORD MOTOR CO.
Connect the generator B+ cable and electrical connector and install the nut.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 94: Locating Generator B+ Cable, Electrical Connector And Nut
  Courtesy of FORD MOTOR CO.
Connect the oil pressure sender electrical connector.

Fig 95: Locating Oil Pressure Sender Electrical Connector
Courtesy of FORD MOTOR CO.
If equipped, attach the block heater wiring harness retainers to the oil level indicator tube and remove the harness.

Fig 96: Locating Block Heater Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
If equipped, connect the block heater electrical connector.

Fig 97: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connector.

Fig 98: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the upper intake manifold and install the 8 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
  
  Fig 99: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Connect the throttle body coolant hose.

Fig 100: Locating Throttle Body Coolant Hose Clamp
Courtesy of FORD MOTOR CO.
Connect the electronic throttle body electrical connector.

Fig 101: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the crankcase vent hose to the upper intake manifold.

Fig 102: Locating Crankcase Vent Hose To Upper Intake Manifold Clamp
Courtesy of FORD MOTOR CO.
Attach the wiring harness pin-type retainer to the upper intake manifold.

Fig 103: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Connect the manifold actual pressure (MAP) sensor electrical connector and the pin-type retainer.

Fig 104: Locating Manifold Actual Pressure Sensor Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.

NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.

Fig 105: Identifying Lower Half Of Lifting Hook

Courtesy of FORD MOTOR CO.

Install the lower half of the special tool.
Install the upper half of the special tool.

Fig 106: Identifying Upper Half Of Lifting Hook
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 107: Identifying Special Tools (134-00243)
Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 108: Identifying Special Tools (303-050 And 014-0001)
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable engine crane, remove the engine from the engine stand.

Fig 109: Identifying Special Tools
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the seal lips and seal bore with clean engine oil before installing.

Fig 110: Identifying Special Tools (303-384 And 303-178)

Courtesy of FORD MOTOR CO.

Using the special tools, install the crankshaft rear seal.
Install the engine-to-transaxle separator plate.

Fig 111: Locating Engine-To-Transaxle Separator Plate
Courtesy of FORD MOTOR CO.
Position the flexplate and install the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).
  
  Fig 112: Locating Flexplate And Bolts
  Courtesy of FORD MOTOR CO.