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Section 1805 (Engine - 4.6L (2V) - F-150): Assembly: Engine

WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000351
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000245
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GF0000313
 Installer, Crankshaft Front Seal 303-635
GF0000314
 Installer, Front Cover Seal 303-335 (T88T-6701-A)
GF0000361
 Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
GF0000316
 Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH)
GF0000320
 Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
GF0000318
 Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH)
GF0002625
 Compressor, Valve Spring 303-452 (T91P-6571-AH)
GF0000434
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
GF0000362
 Alignment Pins, Cylinder Head 303-1040
GF0000400
 Holding Tool, Crankshaft 303-448 (T93P-6303-A)
GF0000339
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Gasket Remover
ZC-30		 -
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Gasket Maker
TA-16		 WSK-M2G348-A5
Instant Gel Adhesive
TA-19		 WSK-M2G402-A4
Threadlock 262
TA-26		 WSK-M2G351-A6
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)		 WSS-M97B51-A1
Hydraulic Chain Tensioner Retaining Clip
1L3Z-6P250-AA		 -
Fig 1: Identifying Engine Components - Upper End
GF0002705Courtesy of FORD MOTOR CO.
Item Part Number Description
1 6766 Oil filler cap
2 6K817 Crankcase ventilation hose
3 6A666 Positive crankcase ventilation (PCV) valve
4 6582 Valve cover - RH
5 6B280 Camshaft bearing cap
6 N811085 Camshaft sprocket bolt - RH
7 N806164 Camshaft sprocket bolt washer - RH
8 6256 Camshaft sprocket - RH
9 6265 Camshaft sprocket spacer - RH
10 6250 Camshaft - RH
11 14465 Coolant hose
12 W704925 Heater outlet tube stud
13 18663 Heater outlet tube
14 12405 Spark plug (8 required)
15 9430 Exhaust manifold - RH
16 9448 Exhaust manifold gasket - RH
17 6051 Cylinder head gasket - RH
18 6049 Cylinder head - RH
19 6758 Crankcase vent tube
20 N806183 Valve cover bolt (8 required)
21 W705782 Valve cover bolt
22 W705644 Valve cover stud (13 required)
23 6A505 Valve cover - LH
24 N807352 Camshaft bearing cap bolt (26 required)
25 6B280 Camshaft bearing cap
26 6C501 Hydraulic lash adjuster (16 required)
27 6529 Roller follower (16 required)
28 5618 Valve spring retainer key (32 required)
29 6514 Valve spring retainer (16 required)
30 6513 Valve spring (16 required)
31 6A517 Valve stem seal (16 required)
32 N811085 Camshaft sprocket bolt - LH
33 N806164 Camshaft sprocket bolt washer - LH
34 6256 Camshaft sprocket - LH
35 6265 Camshaft sprocket spacer - LH
36 6A274 Camshaft - LH
37 14B102 Cylinder head temperature (CHT) sensor jumper harness
38 6G004 CHT sensor
39 6507 Intake valve (8 required)
40 6505 Exhaust valve (8 required)
41 W707747 Exhaust manifold stud (16 required)
42 9Y431 Exhaust manifold gasket (2 required)
43 9431 Exhaust manifold - LH
44 W701706 Exhaust manifold nut (16 required)
45 W704594 Cylinder head positioning dowel (4 required)
46 6083 Cylinder head gasket - LH
47 6050 Cylinder head - LH
48 6010 Cylinder block
Fig 2: Identifying Engine Induction System Components
GF0002706Courtesy of FORD MOTOR CO.
Item Part Number Description
1 9E498 Vacuum harness
2 N811425 Fuel rail bolt (4 required)
3 9F792 Fuel rail
4 W704693 Thermostat housing bolt (2 required)
5 8594 Thermostat housing
6 N806807 Thermostat O-ring seal
7 8575 Thermostat
8 W711062 Ignition coil bolt (8 required)
9 9F593 Fuel injector (8 required)
10 12A366 Ignition coil (8 required)
11 9Y456 Exhaust gas recirculation (EGR) system module
12 9S455 Intake manifold
13 W503301 Intake manifold bolt (9 required)
14 9E930 Throttle body gasket
15 9F991 Throttle body assembly
16 W701592 Throttle body bolt (4 required)
17 9439 Intake manifold gasket (2 required)
18 9D477 EGR system module-to-exhaust manifold tube
Fig 3: Identifying Engine Components - Lower End
GF0002707Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W500225 Knock sensor (KS) bolt
2 12A699 KS
3 6152 Lower compression ring (8 required)
4 6161 Inner oil control ring (8 required)
5 6150 Upper compression ring (8 required)
6 6159 Outer oil control rings (16 required)
7 6135 Piston pin (8 required)
8 6110 Piston (8 required)
9 6140 Piston pin retainer (16 required)
10 6200 Connecting rod assembly (8 required)
11 6211 Connecting rod bearing (16 required)
12 6A341 Crankshaft thrust washer - upper
13 6333 Crankshaft bearing - upper (5 required)
14 6303 Crankshaft
15 6K302 Crankshaft thrust washer - lower
16 6A338 Crankshaft bearing - lower (4 required)
17 6325 Crankshaft main bearing cap (5 required)
18 6325 Crankshaft main bearing cap bolt (9 required)
19 6325 Crankshaft main bearing cap bolt (10 required)
20 N806155 Oil pump screen and pickup tube bolt (2 required)
21 6622 Oil pump screen and pickup tube
22 6K258 Crankshaft main bearing cap stud
23 N806180 Oil pump screen and pickup tube spacer
24 N605904 Oil pump screen and pickup tube bolt
25 6A636 Oil filter adapter gasket
26 6881 Oil filter adapter
27 6A636 Oil filter adapter bolt (4 required)
28 6A636 Oil filter
29 6710 Oil pan gasket
30 6675 Oil pan
31 W701605 Oil pan bolt (16 required)
32 6621 Oil pump bolt (3 required)
33 6621 Oil pump
34 N806168 Flexplate bolt (6 required)
35 6375 Flexplate
36 6701 Crankshaft oil slinger
37 6310 Crankshaft rear seal
38 N806155 Crankshaft rear oil seal retainer bolt (6 required)
39 6K318 Crankshaft rear oil seal retainer
40 6010 Cylinder block
Fig 4: Identifying Engine Components - Front End
GF0002708Courtesy of FORD MOTOR CO.
Item Part Number Description
1 N806282 Coolant pump pulley bolt (4 required)
2 8A528 Coolant pump pulley
3 N806177 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 N808102 Accessory drive idler pulley bolt
6 19A216 Accessory drive idler pulley
7 N804178 Radio ignition interference capacitor nut
8 18801 Radio ignition interference capacitor
9 N806300 Engine front cover stud (5 required)
10 W701512 Crankshaft pulley bolt
11 N806165 Crankshaft pulley washer
12 6316 Crankshaft pulley
13 6700 Crankshaft front seal
14 N806177 Engine front cover bolt
15 N808586 Engine front cover stud
16 W706508 Engine front cover stud
17 W706447 Power steering pump bolts (2 required)
18 W710927 Power steering pump bolt
19 3A696 Power steering pump
20 N806155 Camshaft position (CMP) sensor bolt
21 6B288 CMP sensor
22 6C088 Engine front cover
23 12A227 Ignition pulse wheel
24 N806177 Timing chain tensioner bolt (4 required)
25 6L266 Timing chain tensioner - RH
26 6L253 Tensioner arm - RH
27 6268 Timing chain - RH
28 6M256 Timing chain guide - RH
29 6M269 Timing chain tensioner - LH
30 6L253 Tensioner arm - LH
31 N804958 Timing chain guide bolt
32 6B274 Timing chain guide - LH
33 N606527 Timing chain guide bolt
34 6268 Timing chain - LH
35 6306 Crankshaft sprocket
36 6010 Cylinder block
  1. Record the main bearing code found on the front of the engine block.
    2. Fig 5: Identifying Main Bearing Code Found On Front Of Engine Block
    G04583819Courtesy of FORD MOTOR CO.
  2. Record the main bearing code found on the crankshaft counterweight.
    3. Fig 6: Identifying Main Bearing Code Found On Crankshaft Counterweight
    GF0002709Courtesy 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.
    4. Fig 7: Identifying 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 to determine the required bearing grade for each main bearing.
    5. Fig 8: Identifying Bearing Select Fit Chart (Oversize Bearings)
    G04583822Courtesy 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.
    6. 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.
  6. Install the crankshaft onto the upper crankshaft main bearings.
    7. Fig 9: Locating Crankshaft Onto Upper Crankshaft Main Bearings
    GF0002710Courtesy of FORD MOTOR CO.
    NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
  7. Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing.
    8. Fig 10: Locating Crankshaft Upper Thrust Washer At Back Of Upper Main Bearing
    GF0002711Courtesy of FORD MOTOR CO.
    NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.
  8. Install the rear main bearing cap.
    9. Fig 11: Locating Rear Main Bearing Cap
    GF0002712Courtesy of FORD MOTOR CO.
  9. 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.
  10. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    11. Fig 12: Identifying Main Bearing Cap Fasteners Tightening Sequence
    GF0002713Courtesy of FORD MOTOR CO.
  11. Tighten the jack screws against the cylinder block in the sequence shown, in 2 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    12. Fig 13: Identifying Jack Screws Tightening Sequence
    GF0002714Courtesy of FORD MOTOR CO.
  12. Install the side bolts and tighten them in the sequence shown.
    • Tighten to 21 Nm (15 lb-ft).
    13. Fig 14: Identifying Side Bolts Tightening Sequence
    GF0002715Courtesy of FORD MOTOR CO.
  13. Assemble the 8 pistons. For additional information, refer to Piston  in this article.
    14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    NOTE: The next 3 steps are for all 8 connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown.
    NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.
  14. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
    15. Fig 15: Using Special Tools To Install Piston And Connecting Rod Assembly
    G03920388Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
  15. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
    16. Fig 16: Identifying Special Tool
    G03920389Courtesy of FORD MOTOR CO.
    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.
  16. Position the lower bearing and connecting rod, and install the new bolts loosely.
    17. NOTE: Main bearing caps are removed for clarity.
  17. 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.
    18. Fig 17: Identifying Connecting Rod Bearing Caps Tightening Sequence
    G03920390Courtesy of FORD MOTOR CO.
  18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    19. Fig 18: Identifying Oil Pump Bolts Tightening Sequence
    G03962526Courtesy of FORD MOTOR CO.
  19. Install the pickup tube spacer.
    • Tighten to 25 Nm (18 lb-ft).
    20. Fig 19: Locating Pickup Tube Spacer
    GF0002716Courtesy 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 with the O-ring with clean engine oil.
  20. Position the oil pump screen and pickup tube and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    • Tighten to 10 Nm (89 lb-in).
    21. Fig 20: Locating Oil Pump Screen And Pickup Tube
    G03962527Courtesy of FORD MOTOR CO.
    NOTE: Clean and inspect the mating surfaces, and install a new gasket.
  21. Position the oil filter adapter and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    22. Fig 21: Identifying Oil Filter Adapter
    GF0002717Courtesy 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.
  22. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
    23. Fig 22: Locating Cylinder Head And Gaskets Using Special Tool
    G03920395Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  23. Tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    • Stage 3: Tighten an additional 90 degrees.
    24. Fig 23: Identifying Cylinder Head Bolts Tightening Sequence
    GF0002718Courtesy of FORD MOTOR CO.
  24. Install 8 new RH exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (9 lb-ft).
    25. Fig 24: Locating RH Exhaust Manifold-To-Cylinder Head Studs
    GF0002687Courtesy of FORD MOTOR CO.
  25. Install the new RH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    26. Fig 25: Identifying RH Exhaust Manifold Nuts Tightening
    G03962505Courtesy of FORD MOTOR CO.
    CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
  26. Position the RH engine support insulator and install the bolts.
    • Apply threadlock to the bolt threads prior to installation.
    • Tighten to 63 Nm (46 lb-ft).
    27. Fig 26: Identifying RH Engine Support Insulator Bolts
    G03933620Courtesy of FORD MOTOR CO.
    CAUTION: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign material prior to installation.
  27. Position the LH engine support insulator and install the bolts.
    • Apply threadlock to the bolt threads prior to installation.
    • Tighten to 63 Nm (46 lb-ft).
    28. Fig 27: Locating LH Engine Support Insulator Bolts
    GF0002692Courtesy 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.
  28. Compress the tensioner plunger, using a vise.
    29. Fig 28: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  29. Install a retaining clip on the tensioner to hold the plunger in during installation.
    30. Fig 29: Identifying Retaining Clip On Tensioner
    G03881580Courtesy of FORD MOTOR CO.
  30. Remove the tensioner from the vise.
  31. 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.
    32. Fig 30: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  32. Install the crankshaft sprocket, making sure the flange faces forward.
    33. Fig 31: Identifying Crankshaft Sprocket
    G03919967Courtesy of FORD MOTOR CO.
  33. Install the timing chain guides.
    • Position the LH timing chain guide.
    • Install and tighten the LH bolts.
    • Position the RH timing chain guide.
    • Install and tighten the RH bolts.
    • Tighten to 10 Nm (89 lb-in).
    34. Fig 32: Identifying Timing Chain Guides
    G03962457Courtesy 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.
    35. Fig 33: Identifying LH And RH Camshaft Timing Mark Position
    G04583473Courtesy of FORD MOTOR CO.
    NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
  35. Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
    36. Fig 34: Positioning Crankshaft No. 1 Cylinder Is At TDC With Special Tool
    GF0002621Courtesy of FORD MOTOR CO.
  36. Remove the Crankshaft Holding Tool.
  37. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    38. Fig 35: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  38. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    39. Fig 36: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  39. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    40. Fig 37: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
    GF0002719Courtesy of FORD MOTOR CO.
  40. Remove the retaining clip from the LH timing chain tensioner.
    41. Fig 38: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  41. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    42. Fig 39: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  42. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    43. Fig 40: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
    44. Fig 41: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
    GF0002720Courtesy of FORD MOTOR CO.
  44. Remove the retaining clip from the RH timing chain tensioner.
    45. Fig 42: Identifying Retaining Clip And Timing Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  45. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    46. Fig 43: Identifying Copper (Marked) Chain Links And Dots On Crankshaft Sprockets And Camshaft Sprockets
    G03962922Courtesy of FORD MOTOR CO.
  46. Install the crankshaft sensor ring on the crankshaft.
    47. Fig 44: Locating Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    NOTE: Camshaft roller follower is shown removed for clarity.
  47. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    48. Fig 45: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    NOTE: The camshaft roller followers must be reinstalled in their original locations.
    NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
    NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
  48. Use the special tool to compress the valve springs and install the camshaft roller follower.
    49. Fig 46: Using Special Tool To Compress Valve Springs And Installing Camshaft Roller Follower
    GF0002626Courtesy of FORD MOTOR CO.
    NOTE: The camshaft roller followers must be installed in their original locations.
    NOTE: Lubricate the camshaft roller follower with clean engine oil prior to installation.
  49. Repeat the previous 3 steps for each camshaft roller follower.
    50. 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 with 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.
  50. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
    51. Fig 47: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
    GF0002721Courtesy of FORD MOTOR CO.
  51. 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.
    52. Fig 48: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  52. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 49: Identifying Engine Front Cover Tightening Sequence
    GF0002614Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 53
    6 W706508 Stud Hex Shoulder Pilot, M8 x 1.25 x 50- M6 x 1 x 10
    7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 - M6 x 1 x 86.35
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53
    12 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    13 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    14 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    15 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    53. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  53. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    54. Fig 50: Locating Bolt And LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
    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.
  54. Install the coolant pump.
    1. Lubricate the new O-ring seal using clean 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.
    • Tighten to 25 Nm (18 lb-ft).
    55. Fig 51: Installing Coolant Pump
    GF0002722Courtesy of FORD MOTOR CO.
  55. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    56. Fig 52: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  56. Using the special tools, install a new crankshaft front seal into the engine front cover.
    57. Fig 53: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    NOTE: If 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. 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.
  57. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    58. Fig 54: Identifying Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  58. Use the special tool to install the crankshaft pulley.
    59. Fig 55: Using Special Tool To Install Crankshaft Pulley
    G03920552Courtesy of FORD MOTOR CO.
  59. 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.
    60. Fig 56: Installing Crankshaft Pulley Bolt
    GF0002723Courtesy of FORD MOTOR CO.
  60. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    61. Fig 57: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
    G03933688Courtesy of FORD MOTOR CO.
  61. Position the accessory drive belt tensioner and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    62. Fig 58: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy 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.
  62. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  63. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
    64. Fig 59: Identifying Proper Valve Cover Gasket Sealant Application
    G03948210Courtesy of FORD MOTOR CO.
    NOTE: If 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. 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.
  64. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    65. Fig 60: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03947580Courtesy of FORD MOTOR CO.
  65. Position the LH valve cover and gasket and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).
    Fig 61: Identifying Valve Cover Tightening Sequence
    GF0002591Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    4 W705782 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    6 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    7 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
  66. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
    67. Fig 62: Identifying Valve Cover Gasket Groove
    G03905398Courtesy of FORD MOTOR CO.
    NOTE: If 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. 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.
  67. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    68. Fig 63: Applying Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
    G03947588Courtesy of FORD MOTOR CO.
  68. Position the RH valve cover and gasket and tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).
    Item Part Number Description
    1 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    2 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    3 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    4 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    5 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    6 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    7 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    8 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    9 W705644 Pin Stud, Hex Flange Pilot, M6 x 1 x 73.76
    10 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    11 N806183 Bolt, Hex Flange Head Pilot, M6 x 1 x 42.5
    69. Fig 64: Identifying Valve Cover Tightening Sequence
    GF0002596Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the O-ring seal with clean engine oil.
  69. 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.
    • Tighten to 10 Nm (89 lb-in).
    70. Fig 65: Locating Oil Level Indicator Tube Bolts
    GF0000353Courtesy of FORD MOTOR CO.
  70. Install 8 new LH exhaust manifold-to-cylinder head studs.
    • Tighten to 12 Nm (9 lb-ft).
    71. Fig 66: Locating LH Exhaust Manifold-To-Cylinder Head Studs
    GF0002686Courtesy of FORD MOTOR CO.
  71. Install the new LH exhaust manifold gasket and the exhaust manifold. Tighten the new nuts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
    72. Fig 67: Identifying LH Exhaust Manifold Nut Tightening Sequence
    GF0002633Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  72. Install the radio frequency interference capacitors and the nuts.
    • Tighten to 25 Nm (18 lb-ft).
    73. Fig 68: Identifying Radio Frequency Interference Capacitors
    G03906363Courtesy of FORD MOTOR CO.
    NOTE: Do not reuse the O-ring seal.
    NOTE: Lubricate the O-ring seal with clean engine coolant.
  73. Slide the heater outlet tube forward with the new O-ring seal into the cylinder block.
    74. Fig 69: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
    GF0000368Courtesy of FORD MOTOR CO.
  74. Install the heater outlet tube studs.
    • Tighten to 25 Nm (18 lb-ft).
    75. Fig 70: Locating Heater Outlet Tube Studs
    GF0002689Courtesy of FORD MOTOR CO.
  75. Connect the coolant hoses to the heater outlet tube.
    76. Fig 71: Locating Coolant Hoses To Heater Outlet Tube
    GF0002688Courtesy of FORD MOTOR CO.
  76. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  77. Connect the RH radio ignition interference capacitor electrical connector.
    78. Fig 72: Locating RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  78. Connect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    79. Fig 73: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  79. Connect the engine oil pressure (EOP) switch electrical connector.
    80. Fig 74: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    GF0002681Courtesy of FORD MOTOR CO.
  80. Connect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    81. Fig 75: Locating Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer
    GF0002682Courtesy of FORD MOTOR CO.
  81. Connect the CMP sensor electrical connectors.
    82. Fig 76: Locating Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  82. Install the special tool.
    83. Fig 77: Identifying Special Tool
    G03962845Courtesy of FORD MOTOR CO.
  83. Using a suitable floor crane, remove the engine from the engine stand.
    84. 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.
  84. 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.
    85. NOTE: The rear crankshaft seal retainer plate does not have a sealant groove. Gasket maker must be applied to the rear crankshaft seal retainer plate mating surface on the engine block.
  85. Apply a bead of gasket maker to the rear crankshaft seal retainer plate mating surface on the engine block.
    86. Fig 78: Applying Bead Of Gasket Maker To Rear Crankshaft Seal Retainer
    GF0002646Courtesy of FORD MOTOR CO.
  86. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.
    87. Fig 79: Locating Crankshaft Rear Seal Retainer Plate Bolts
    GF0000369Courtesy of FORD MOTOR CO.
  87. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    88. Fig 80: Identifying Crankshaft Rear Seal Retainer Plate Bolt Tightening Sequence
    GF0002724Courtesy 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.
  88. 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.
    89. NOTE: If 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. 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.
  89. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
    90. Fig 81: Applying Silicone Gasket And Sealant
    GF0000322Courtesy of FORD MOTOR CO.
    NOTE: If 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. 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.
  90. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
    91. Fig 82: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Mating Surface
    G03920465Courtesy of FORD MOTOR CO.
  91. Install the oil pan gasket and the oil pan and loosely install the bolts.
    92. Fig 83: Positioning New Oil Pan Gasket And Oil Pan
    GF0000323Courtesy of FORD MOTOR CO.
  92. 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.
    93. Fig 84: Identifying Oil Pan Bolt Tightening Sequence
    G03920110Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
  93. Using the special tools, install a new crankshaft rear seal.
    94. Fig 85: Using Special Tools To Install New Crankshaft Rear Seal
    G04583928Courtesy of FORD MOTOR CO.
  94. Using the special tools, install a new crankshaft rear oil slinger.
    95. Fig 86: Installing Crankshaft Rear Oil Slinger Using Special Tools
    G03920154Courtesy of FORD MOTOR CO.
  95. Install the flexplate and the 6 bolts. Tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
Fig 87: Identifying Tightening Sequence Of Flexplate Bolts
G03947697Courtesy of FORD MOTOR CO.
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